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Rescue jumper
In common parlance, power engineers call such pipelines a jumper. The diameter of the jumper pipe is 108 mm. It was installed between the pipeline of the Novo-Sverdlovsk Thermal Power Plant and the pipeline of one of the central heating stations in Yekaterinburg. The measure is precautionary. In this way, operators protected consumers and, in fact, themselves from possible emergency situations. For example, at the beginning of 2016, an accident occurred at this central heating station: due to voltage surges in the electrical network, the automation turned off the network pumps of the heating station, hot water, accordingly, stopped flowing into the houses, which almost led to freezing of the risers on the landings. Now the jumper will protect the house from all sorts of “bad things.”
The author of the idea is Andrey Kuznetsov, deputy head of the heating networks district No. 4 of the ETK. The new scheme he proposed for the operation of central heating stations in an emergency situation - for example, in the event of a shutdown of the same network pumps - allows coolant to be delivered to homes at the required temperature and at the appropriate pressure via a jumper directly from the thermal power plant, bypassing the heating station with non-working pumps.
Naturally, Andrei Kuznetsov’s idea brought to life is, first of all, to increase the reliability of energy supply to consumers. However, this is not all. Using a jumper, it is very convenient to maintain the optimal temperature of the coolant, and by correctly maintaining the temperature schedule of the heating network from the central heating station, the company will annually save about 2.77 million rubles.
About import substitution
Another rationalization proposal of Andrei Kuznetsov was implemented - this time at another central heating point. The essence of this rationalization proposal is simple - to carry out import substitution of end couplings connecting the electric motor and the central heating pump. The need was obvious, because foreign-made consumable parts are very expensive and at the same time take a very long time to be delivered. So the deputy head of the heating networks district suggested doing them somewhere closer to home, in Yekaterinburg. We turned to the Ural RTI Plant, which “imported” the required couplings at reasonable prices and on time. Today it can already be stated that locally produced couplings are no worse than imported ones - they worked through the heating season without any problems. And the estimated economic effect from this rationalization proposal is 0.33 million rubles per year. In the future, Andrey Kuznetsov’s ideas are planned to be implemented at other central heating centers in the city.
Svetlana Kazakova
Inventions, innovation proposals, and utility models are of great importance in the process of improving the technologies used. All of them act as objects of technical creativity. However, the most widespread of them are rationalization proposals. In an enterprise striving for the most effective achievement of its goals, they are by no means the least important. Let us consider this category in more detail below.
Positive points
Thanks to the rationalization proposal, an existing technical solution can be improved, the equipment used can be modernized and adapted to certain production conditions. In addition, with the help of such implementations, it becomes possible to eliminate certain errors of designers or constructors. According to data provided in specialized publications, rationalization proposals have recently provided about 70% of the total savings in the Russian economic system.
Definition
In the previous provision, a rationalization proposal was a technical solution that was useful and new for the production, institution or organization to which it was directed. It involved changing technology, the design of products or equipment, and the composition of the material. In addition, certain types of decisions were given that belonged to the category under consideration.
According to this provision, the rationalization proposal had such characteristics as usefulness, novelty and technical solution. In current recommendations, the definition is given in a slightly modified form. In particular, a rationalization proposal is a managerial, organizational or technical solution that is recognized as useful and new for a given structure. From the definition it is clear that only the first part has changed. Thus, the rationalization proposal is no longer limited exclusively to the area of technical methods for solving current practical problems. 
Characteristic
First of all, it should be noted that the proposal, which is submitted as a rationalization proposal, should not simply pose any task. Through it, it is necessary to reveal specific ways to solve the problem. A situation should be created in which, thanks to the rationalization proposal, it would be possible to obtain the expected result with maximum efficiency and with the least losses. Decisions that merely state a need, limit themselves to indicating the advisability of carrying out a particular event or the positive result that can be achieved during its implementation, and so on, will not be recognized as useful and new.
Rationalization proposals, examples of which will be given below, include a fundamental answer. The solution should be so specific that there is no need to make any guesses or assumptions. The proposal reveals the essence of the author's idea, and its execution does not require additional creative modifications. This condition will be considered fulfilled if the solution and materials explaining it contain sufficient information for the practical implementation of the plan using known design (construction) methods.
Methods of execution
Providing a solution to a problem can be carried out using managerial, organizational, technical means or a combination of them. Among technical proposals, the predominant ones are those that relate to design changes in products, production technologies, equipment used, or material composition. Such solutions are focused on improvement and modernization. At the same time, it is not excluded that a project that involves the introduction of new technology or equipment can be recognized as an innovation proposal. Management and organizational decisions contribute to obtaining effective results through the implementation of appropriate activities or optimization of management.
What could be the rationalization proposals?
Various examples can be given. Thus, the decision may concern the allocation of labor resources and document flow. Rationalization proposals can be made regarding equipment repairs, changes in work schedules, and so on. The solution can also have an organizational and technical focus, combining different elements. Thus, thanks to the rationalization proposal, it is possible to achieve an improvement in the condition of places for workers, optimal placement of equipment, effective separation or combination of production operations, and so on. 
Novelty
This is the second essential sign of a useful solution. A rationalization proposal, unlike inventions, is subject to the requirement of local novelty. This means that this attribute must be present within those companies to which decisions are sent. A proposal will be considered new if, before its submission, the enterprise did not know about it to an extent that would be sufficient for its implementation.
Championship
Novelty is determined in accordance with a specific time period. Regarding rationalization proposals, the concept of primacy is used. It is determined by the date of receipt of a correctly completed application for project implementation. The primacy will be recognized by the author who did it first according to the established procedure. A proposal can be opposed only by information that reveals the essence of this or an identical project that became known before the specified date of primacy. 
Information Fund
The rationalization proposal includes:
Authorship
It must be borne in mind that a useful and new proposal must be the result of the creative activity of the person submitting it. Often in special publications it is proposed to consider this feature as an independent criterion for the “protectability” of a decision. However, according to a number of experts, this is not particularly necessary due to the fact that all intellectual property for which copyright is recognized must have a creative orientation.
Thus, it is initially believed that all objects of this kind, including the rationalization proposal, are the result of the creative activity of the creators themselves and are not borrowed from open sources. Of course, the latter should be obvious. Refusal to recognize a proposal as a rationalization based on the establishment of borrowing, therefore, is allowed only if this fact is proven or is not directly disputed by the applicant himself.
4.2. Rationalization proposals as an integral part of the enterprise’s activities
The rationalization movement in Tatneft has existed almost since the very inception of the company. Even today, management does its best to stimulate its employees to creative work of thought. The planned approach also plays a significant role in this - every year the management departments are given the number of improvement proposals that need to be introduced into production. And it must be said that NGDU Bavlyneft consistently not only fulfills, but also exceeds this plan.
The importance of innovation cannot be overestimated. This gives development to the production process, improves working conditions, increases its safety, is reflected in the rating of the workshop and affects the material and moral incentives of workers. The economic effect of innovations is also important. According to rough calculations, the rationalization proposals made it possible to save about 400 thousand rubles. At the same time, not all successful ideas introduced into production can be calculated in monetary terms, since some of them are aimed at improving working conditions.
4.3. Economic efficiency from the implementation of otm, gtm
Every year, oil and gas producing enterprises develop and approve measures for energy efficient economy. One of these measures is the introduction of pumps with shortened suspension (reducing the depth of descent of downhole pumps) in production wells.
I At NGDU "Bavlyneft" some wells are in operation that operate at high dynamic levels. Reducing the suspension depths of pumps in these wells leads to a reduction in energy costs for lifting liquid, and optimal operation of deep-well pumping equipment is achieved.
The layout is intended to increase the overhaul period of operation of sucker rod pumping equipment for oil production from oil wells, and helps to increase oil production.
The performance indicators of wells before the introduction of pumps with shortened suspension were taken as a basis for comparison.
Table 4.2.
Introduction of pumps with shortened suspension
|
Name of indicators |
Basic option |
New option |
Deviation |
|||
|
Scope of implementation | ||||||
|
Suspension lowering depth | ||||||
|
Duration of hoisting operations | ||||||
|
Electricity consumption | ||||||
|
Energy costs |
thousand rubles/year | |||||
|
Specific amount of ORS at wells | ||||||
As a result of the introduction of pumps with shortened suspension, changes in indicators occurred: the depth of suspension descent was reduced by 11%, which amounted to 120 m, and the duration of lowering and lifting operations was reduced by 5%, which amounted to 1 hour. Electricity costs decreased by 8.4 thousand rubles/year, which amounted to 4683.3 kW/h, that is, by 8.7%. The volume of implementation has remained unchanged, and the technology for testing existing wells equipped with pumps with shortened suspension is carried out without the involvement of well drilling crews.
Table 4.3.
Calculation of the economic effect of introducing pumps with shortened suspension
|
Name of indicators |
Meaning |
||
|
ORS costs | |||
|
Resuscitation costs | |||
|
Operating cost savings | |||
|
Income tax | |||
|
Income tax | |||
|
Net profit | |||
|
Duration of work | |||
|
Basic and additional salary, with social insurance contributions |
The results of the calculations show that operating cost savings amount to 741.7 thousand rubles and net profit – 593.4 thousand rubles.
Thus, the economic effect is achieved through:
reducing energy consumption costs;
reducing the height of liquid rise.
Using this method, the enterprise fulfills its objectives in the field of cost savings in terms of resource conservation and an economic effect is achieved.
II Application of variable heating mode, with a decrease in temperature at night and on weekends in enterprise buildings:
automatic regulation of thermal energy consumption is installed, which significantly increases the efficiency of its use;
comfortable indoor conditions and uniform distribution of thermal energy throughout the building are ensured;
the temperature of the return network water is maintained according to the schedule;
heat supply modes for buildings are selected and adjusted;
any temperature regime is set and maintained, for example, the temperature in the building is lowered in order to save money during non-working hours or on weekends;
Excessive heating is excluded in the autumn and spring periods;
the hydraulic mode of the heat supply system is improved.
For comparison, we take automatic regulation of thermal energy consumption and the usual mode of heat supply to buildings according to the temperature schedule (Table 4.4).
Table 4.4
|
Name of indicators |
Unit measurements |
Option basic normal heat supply mode |
New option automatic regulation |
Saving |
|||
|
Thermal energy | |||||||
|
Net profit | |||||||
III Replacement of transformers with higher power with smaller ones
Transformers with increased power are installed at oil production facilities. Replacing them with a lower power will reduce the no-load losses of the transformer and ensure a reduction in energy consumption.
Depending on the load, power losses of power transformers amount to about 4% of the rated power. Replacing transformers with a power of 100 kW by 63 kW, and 63 kW by 25 kW will reduce electricity losses.
25 kW transformers are installed instead of 63 kW transformers, which then replace transformers with a power of 100 kW; released 100 kW transformers are transferred to the reserve fund or installed at newly commissioned facilities, or sold (Table 4.5).
Table 4.5
Technical and economic advantages
|
Name of indicators |
Unit measurements |
Basic option |
New option |
Saving |
|
Transformer replacement | ||||
|
Transmission power of 100 kVA is released | ||||
|
Cost of transfers. 25kVA - 5 pcs. | ||||
|
Electricity | ||||
|
Electricity | ||||
|
Replacement costs | ||||
|
Increased depreciation costs | ||||
|
Reduced operating costs | ||||
|
Net profit |
thousand rubles |
Table 4.6
Analysis of energy saving measures aimed at saving electricity
|
Name of events |
Energy Saving |
Economic |
||
|
The use of variable heating mode, reducing the temperature at night and on weekends in the enterprise building | ||||
|
Replacing transformers with more power with less | ||||
An analysis of these two energy conservation measures aimed at saving electricity (Table 4.6) shows the progress achieved in monetary terms. They total more than 1.7 million rubles. With the help of these measures, the enterprise fulfills its goals in the field of energy saving. Thus, an economic effect is achieved.
Three effective, in our opinion, the development of piles and pile foundations in construction are the technical solutions of the Department of Construction Technology of the Brest State Technical University: pile support (patent of the Republic of Belarus for utility model No. 8603), bored pile (patent No. 8370) and the third development - pile ( patent application of the Republic of Belarus).
The pile support, in comparison with others of a similar purpose, is very simple to manufacture, minimally metal intensive (only the barrel is metal), cheap and technologically advanced to manufacture. On such supports you can erect fences, gates, build country houses, garden buildings and a wide variety of other above-ground structures.
Before being immersed in the well, the pile support is a profile metal pipe 1 with drop-down blades 2 made from sections of the wall cut with longitudinal slots 3 at the lower end of the pipe (Fig. 1). The pipe 1 itself is made of a square box-shaped cross-section (patent No. 8603). It can also be made with a rectangular box section. Both types of box profiles are produced by the domestic industry and they are cheaper than round metal pipes, approximately equal to box profiles in terms of the cross-sectional area of the trunk.
Longitudinal slots 3 are made on the side ribs of the pipe 1 using a milling cutter or cutter on a milling or cutting machine, a gas or kerosene cutter, or even on a sharpening (grinding) machine, as well as manually using a hacksaw. Moreover, the greater the length of the blades 2 and the length of the longitudinal slots 3, the greater the opening of the blades in the well will be and the greater the broadening will be created in the ground.
After drilling a well in the ground with any tool, mechanism, device or machine of the required depth and a larger (compared to the cross-sectional dimensions of the pipe 1) diameter, a lost shoe 4, previously selected from natural or artificial stone in the form of a round boulder, is lowered (dropped) into it or a spherical body, and then begin to open the blades 2 by plugging the pipe 1 (Fig. 2). Due to the large cross-sectional dimensions of the shoe 4 (compared to the cross-sectional dimensions of the pipe 1), but smaller compared to the diameter of the well, the blades 2 of the pipe 1 begin to slide and move apart along the shoe 4 (boulder) to the sides and crash into the walls of the well , creating a widening in it and the pile support itself. After sufficient opening of the blades 2 in the well (which can be judged visually and instrumentally by the sediment of the pipe 1 in the well), they begin layer-by-layer backfilling of the well with soil, sand, and crushed stone with careful compaction of each layer. As a result, a pile support is formed in the soil with a very high bearing capacity on the foundation soil under the influence of both vertical and horizontal pressing loads.
BrSTU has also developed the second (patent of the Republic of Belarus No. 8370) and third (patent application of the Republic of Belarus) options for constructing pile supports (drilled pile and pile), which differ from the first in the shape of the shaft and the material of the pile.
In a bored pile, the trunk is made round from a metal pipe 1 with opening blades 2, made from sections of the wall cut with longitudinal slots 3 at the lower end of the trunk (Fig. 3). Subsequently, under the influence of driving, the blades 2 in the well open, turning into a pile support in the ground (Fig. 4).
In the pile, the trunk 1 is made of wood from round timber, and the opening blades 2 are made of metal, attached to the trunk with nails or screws 5 (Fig. 5). The opening of the blades 2 in the well is also carried out using the driving method (Fig. 6).
In other respects, the designs of the pile support, bored pile and pile are similar, and the technologies for installing them into wells pre-drilled in the ground are similar.
Under certain conditions, all three designs can bring a significant economic effect from implementation in construction practice, in particular on soft soils of the Republic of Belarus.
V.P. Chernyuk, Associate Professor, Department of Construction Technology
Brest State Technical University, Ph.D.
The rationalization movement of IDGC of Center and Volga Region PJSC was revived with renewed vigor in 2008, and in connection with the “Year of the Engineer” it received a new impetus. The main goals of rationalization activities at IDGC of Center and Volga Region were the activation and further development of mass technical creativity of employees as one of the conditions for the innovative development of the company.
Today, IDGC of Center and Volga Region PJSC registers about one hundred technical proposals per year. Proposals recognized as rationalization are applied in the production activities of the branches of the author; at least 10 percent of them are replicated annually in the energy company. Statistical analysis showed that more than 90 percent of suggestions are made by representatives of production personnel. Rationalization is most common among managers and engineering and technical workers with higher professional education, middle age, and professional experience and knowledge.
As Igor Taranov, deputy chief engineer of IDGC of Center and Volga Region PJSC for development and innovation, said, the most popular area of rationalization activity for the company is ensuring reliability, safety and increasing the productivity of the production process.
The leaders in the number of accepted and implemented rationalization proposals at IDGC of Center and Volga Region PJSC over all the years of rationalization activities with individual and collective participation were three employees of the company’s branches.
Category 2 engineer of the relay protection, automation and metrology service of the Vladimir Electric Networks production department of the Vladimirenergo branch, Alexey Tretyakov (pictured), proposed eight developments, including the invention of a flashlight with a magnetic mount and electronic dialing, which increases the safety of work in relay compartments of substations with the possibility of use in places with high background noise, and an attachment - a high-frequency signal amplifier, which allows you to configure, check and troubleshoot RF protection equipment.
The author of seven developments was an engineer of the 2nd category of the information technology service of the Northern Electric Networks production department of the Kirovenergo branch, Vladimir Chernov. The “Electronic Load” device he developed is used as a load device for control discharges of batteries, as well as for testing various DC power sources, improving the quality of work and ease of use. Another invention of Vladimir, “Meter of equivalent series resistance of electrolytic capacitors,” speeds up and simplifies the process of diagnosing faults in communications, telemechanics and computer equipment.
Dmitry Dudin, head of the substation service of the Sernur Electric Networks production department of the Marienergo branch, is the author of five developments. The special container he proposed for preparing a mixture of antioxidant additives such as “Ionol”, “Agidol” accelerates the production of a homogeneous mixture in order to add the resulting liquid to oil-filled equipment to improve dielectric characteristics and extend the service life of transformer oil. The modernization of the VG type vibrograph, invented by Dmitry, improved the recording of time and speed characteristics on MV-35kV of all types in order to obtain accurate data and increase safety when taking characteristics from oil switches.
The company places emphasis not only on successful daily work, but also on the creative potential of the team. The desire to stimulate the involvement of a larger number of workers in the process of mass technical creativity and to increase the percentage of replication has led to the fact that IDGC of Center and Volga Region has introduced a procedure for remunerating authors based on the results of replication of innovative developments: depending on the scale and effect of introducing an innovation, the author receives a bonus. To inform staff about innovative developments, a unified register of all technical solutions has been created, posted on the company’s publicly accessible internal resource.
Wanting to popularize the innovation movement among young professionals, expand the areas of innovation proposals and improve the conditions for the influx of new ideas, IDGC of Center and Volga Region PJSC announced the start of the first stage of the “Best Innovator Engineer” competition.
Employees of branches and teams of authors of the energy company can submit applications for participation in the competition until June 30, 2017. The application is accepted if there is a submitted application for an improvement proposal in accordance with STO 01‑036‑2016.
The company is confident that if you take a broader look at the world and fill your daily work with new ideas, you can benefit not only your colleagues, but also the company as a whole!
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