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Referenz

Explosionsschutz unter Extrembedingungen

Um kundenindividuelle Lösungen anbieten zu können und mit dem Automatisierungstrend der Öl- und Gasindustrie Schritt zu halten, wollte das russische Unternehmen OOO SSTEnergomontazh seine elektrischen Begleitheizanlagen für Pipelines deutlich stärker automatisieren. Mit den explosionsgeschützten Komponenten von WAGO ist das auf einfache wie ökonomische Art und Weise gelungen.

Wenn im äußersten Norden Russlands und in Sibirien der russische Winter eingekehrt, dann werden Landstriche, Leute und Leben in Eis gebannt. Bei -55 °C Außentemperatur, auf die das Thermometer dann gut und gerne schon einmal abfallen kann, gefrieren selbst Flüssigkeiten in Versorgungspipelines. Damit es soweit erst gar nicht kommt, werden auf der gesamten Prozesskette der Erdölförderung und der Verarbeitung von Produkten der russischen Öl-, Gas- und Chemieindustrie elektrische Begleitheizanlagen der Firma OOO „SSTEnergomontazh“ eingesetzt.

So unterstützt Sie WAGO im Ex-Bereich

Das WAGO-I/O-SYSTEM 750 XTR für den Ex-Bereich besteht selbst in extremsten Bedingungen.
Die zulässige Umgebungstemperatur von -40 °C bis +70 °C ermöglicht den Einsatz in allen klimatischen Zonen ohne den Schutz durch Klimageräte.
Die erhöhte Spannungsfestigkeit und Störsicherheit lässt selbst den Einsatz in Mittelspannungsanlagen zu.

OOO „SSTEnergomontazh“ ist Teil der Unternehmensgruppe „SST- Spezielle Systeme und Technologien“, die Marktführer im Bereich Projektierung und Montage von kabelgebundenen elektrischen Begleitheizsystemen sind, die sowohl im privaten als auch im industriellen Sektor eingesetzt werden. Die russischen Werke der Unternehmensgruppe sind europaweit der größte Produzent von Heizkabeln und technischen Geräten zur Temperaturregelung. Seit ihrer Gründung im Jahr 1991 hat die Unternehmensgruppe über 4.000 industrielle Begleitheizanlagen an Objekten oder auf deren Dächern installiert und über 6.000 auf Pipelinesystemen und Reservoiren. Aktuell sorgen Begleitheizsysteme von SST auf einer Strecke von insgesamt über 20.000 Kilometern für einen zuverlässigen Pipelinebetrieb. Dazu halten sie die Produkte in Pipelines und Reservoiren auf einer vorgegebenen Solltemperatur.

Auf dem Weg zum automatisierten Begleitheizbetrieb

Damit die Begleitheizsysteme auch bei -55 °C Außentemperatur zuverlässig ihren Dienst tun, werden mehrere Arten spezieller Heizkabel zwischen der Pipeline und ihrer Wärmedämmschicht verlegt. Dabei werden sowohl Heizkabel eingesetzt, die für eine konstante Leistung ausgelegt sind, als auch selbstregelnde Kabelsysteme. Selbstregelnde Kabelsysteme geben ihre Wärme in Abhängigkeit von den vorliegenden Umweltbedingungen ab. Ihre Vorteile gegenüber Kabeln, die bei konstanter Leistung betriebenen werden: Auch Objekte mit sehr kleiner Ausdehnung können beheizt werden und das bei deutlich höherer Energieeffizienz.

Ebenfalls unmittelbar an der Pipeline installiert sind Sensoren und Temperaturregler, die die Temperatur überwachen und den Heizbetrieb steuern. Für diesen Betrieb der Anlagen automatische Steuerungs- und Regelungssysteme einzusetzen, ist ein Entwicklungsziel, auf das man bei OOO SSTEnergomontazh derzeit großes Augenmerk legt. SST möchte dadurch zum einen kundenspezifische Wünsche erfüllen und maßgeschneiderte Lösungen anbieten können, zum anderen folgt das Unternehmen damit einem deutlichen Trend innerhalb der Öl- und Gasindustrie: Denn, sowohl bei bereits bestehenden, als auch bei Anlagen, die sich aktuell im Aufbau befinden, werden Prozesse der Förderung und des Transports von Produkten zunehmend automatisiert. Ziel ist es, jeden technischen Prozess – auch den der Beheizung – mit den Möglichkeiten zur Selbstdiagnose, Ausgabe von relevanten Informationen an eine Mensch-Maschine-Schnittstelle (HMI), Ausgabe von Meldungen über Notfallsituationen und Statusmeldungen oder zur Erfassung und Archivierung betriebsrelevanter Informationen zu befähigen. Die Steuerungssysteme sollen sich dabei moderner Kommunikationsprotokolle bedienen, Daten über digitale Schnittstellen an das Prozessleitsystem übertragen, via Fernwirkprotokoll aus dem SCADA bedienbar sein sowie Leitstand- und Not-Aus-Funktionalitäten bieten. Überdies sollen sie zuverlässig sein und die Energieeffizienz auf Basis optimierter Berechnungsalgorithmen und abgestimmter Systemeinstellungen verbessern.

Technologisch großen Schritt voraus

Um in der Automatisierung von elektrischen Begleitheizsystemen einen großen Schritt nach vorn zu machen, hat sich OOO SSTEnergomontazh zur Zusammenarbeit mit WAGO entschieden. SST nutzt einige Funktionsmodule aus dem modularen WAGO-I/O-SYSTEM 750, insbesondere Module in explosionsgeschützter Ausführung. „Die Anzahl der Unternehmen, die uns vergleichbare Ausrüstungen zum vergleichbaren Preis anbieten konnten, war sehr gering“, sagt A. W. Mochow, Leiter der Abteilung für die Projektierung von elektrotechnischen Ausrüstungen bei SSTEnergomontazh. „Die meisten Hersteller führen in ihrer Produktpalette lediglich Komponenten für den Einsatz in der Industrie.“ In Systemen zur Beheizung von Industrieanlagen müsse jedoch die Temperatur mit Hilfe eines Sensors überwacht werden, der direkt an der Pipeline installiert sei.

Diese Messstelle befände sich zum einen in einem explosionsgefährdeten Bereich der Gefährdungsklasse 2, zum anderen etwa einen Kilometer entfernt vom Schaltschrank, der selbst im Nicht-Ex-Bereich stehe. Zu diesem Zweck habe SST das Funktionsmodul 750-485 des WAGO-I/O-SYSTEMS verwendet, über das die Temperatursensoren angeschlossen werden können, die für den Betrieb bei normiertem Stromstärkesignal ausgelegt sind. „Das hat es uns ermöglicht, die Stromkreise eigensicher zu halten, ohne dass zu diesem Zweck zusätzliche Barrieren eingesetzt werden mussten“, so Mochow, „überdies konnten wir bis zu 20 % des Raums einsparen, der uns in den Schaltschränken zur Verfügung steht“. Ein weiteres Argument, das für die Lösung aus dem Hause WAGO gesprochen habe: die Programmierung der WAGO-Systeme mittels CoDeSys. Diese Programmierumgebung sei nicht nur eine der am stärksten verbreiteten und universell einsetzbaren SPS-Programmierumgebungen, sondern „sie bietet eine breite Palette an Möglichkeiten für die Umsetzung von Algorithmen, die auf die Aufgaben im Bereich der elektrischen Beheizung zugeschnitten sind“, so Mochow.

Vom Ergebnis überzeugt

Der Leiter der Projektierungsabteilung von SST ist inzwischen zum WAGO-Fan avanciert, beschreibt den Support, den das Unternehmen für seine Produkte anbietet, als qualitativ hochwertig und freut sich über die ständige Aktualisierung der Produktpalette und die Veröffentlichung neuer Programmbibliotheken. „Wir beobachten ständig neue Entwicklungen von WAGO und unterhalten enge geschäftliche Beziehungen mit der Vertretung in Moskau“. Außerdem nähmen die Mitarbeiter von SST an Seminaren teil und blieben mit WAGO durch regelmäßige Treffen auf internationalen Fachmessen in Kontakt. Und letztendlich spräche der Erfolg der Zusammenarbeit für sich, findet Mochow: „Die Praxis bestätigt, dass unsere Erwartungen an WAGO zu 100 % erfüllt wurden. Gegenwärtig betreiben wir mehrere zig zuverlässig funktionierende Systeme in der Unternehmenslandschaft der russischen Öl- und Gasindustrie“.

Autor: Benjamin Böhm | WAGO

Produktübersicht

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WAGO in der Praxis

Referenzen aus dem Explosionsschutz

WAGO setzt als Partner und Innovationsführer viele interessante Projekte um. Erfahren Sie, was wir für kreative und effiziente Lösungen im Bereich Prozess- und Verfahrenstechnik ermöglichen.

Explosives sicher abfüllen

Beim Abfüllen fließfähiger Medien gehört die Feige FILLING GmbH zu den Marktführern. Für die ATEX-Kategorie 1 konzipieren Sie Ex-Lösungen mit WAGO-Technik.

Moderner Tunnelbau

Schmutz, Vibrationen, Hitze: Für die Steuerung ihres Mischladesystems hat die Demostene + Partner AG sich für eine WAGO-Lösungen entschieden, die alles abkann.

Sicher unter Tage

Im Steinkohlebergbau dürfen nur Anlagen zum Einsatz kommen, von denen keine Zündgefahren ausgehen. HAZEMAG & EPR setzt deshalb auf WAGO-Controller.

Ihr Ansprechpartner bei WAGO

Weitere Serviceangebote:

Mehr aus dem Bereich Prozesstechnik

Ganz gleich, ob modulare Prozessautomation, Explosionsschutz, Cyber-Security oder Prozess 4.0 – WAGO bietet Lösungen für jede Herausforderung der Branche.

Modulare Prozessautomation

Wandlungsfähige Produktionsprozesse sind der Schlüssel zu Flexibilität, Effizienz und Losgröße 1. Mit WAGO lassen sich Produktionsmodule individuell und herstellerunabhängig kombinieren.

Energiemanagement

Energiesparen ist gut für die Umwelt und das Geschäft. Wer dabei gut analysiert und agiert, kann nachhaltig profitieren. WAGO ist Ihr Partner für effektives Energiemanagement.

Smart Data

Die Digitalisierung von Bestell- und Produktionsprozessen ist für alle Unternehmen eine große Chance. WAGO unterstützt Sie dabei, alle Potentiale zum Vorteil zu nutzen.

Empfehlungen zum Weiterlesen

WAGO in anderen Branchen

Automatisierungs- und Kontakttechnik von WAGO ist nicht nur im Bereich Prozess- und Verfahrenstechnik vertreten. Erfahren Sie, welche Lösungen WAGO in anderen Branchen bietet.

Marine & Offshore

Moderne Antriebstechnik, die Vernetzung von Teilsystemen – Automatisierung und Digitalisierung sind auf dem Schiff Standard.

Energietechnik

Mithilfe moderner Automatisierungs- und Digitalisierungstechnologien entstehen kommunikative Smart Grids.