Confectionery Factory “Mondelez Ukraine”. Automation and power supply of plant areas

Description

“Mondelez Ukraine” is part of Mondelēz International, an American multinational food company and the world’s largest confectionery producer, according to the official website of “Mondelez Ukraine”.

Until 2014, the company was known as “Kraft Foods Ukraine”. Today, the plant in Trostianets produces chocolate “Korona”, “Milka”, “Barni”, “Picnic”, and cookies BelVita, OREO, Tuc and others.

What was done

1. Modernization of the 10 kV transformer substation. Technical upgrading of the 10 kV transformer substation of the main production building. A new modern SF6-insulated switchgear 8DJH from SIEMENS with microprocessor-based protection and automation devices was installed. The 10 kV substation supplies power to the technological processes of the plant’s main building.

2. Replacement of transformers. In 2020, S-Engineering specialists replaced old oil transformers with new Siemens AG Geafol dry-type transformers compliant with Ecodesign (Directive 209/125/EC). The total capacity of six new transformers is 6000 kVA. All works were carried out without shutting down the plant.

3. Modernization of the recipe station. A complete upgrade of the recipe station responsible for preparing chocolate masses.

Scope of work included:

• Development of project documentation
• Full replacement of technological equipment
• Development and implementation of a modern automation system with SCADA integration
• Full replacement of liquid ingredient pipelines (3 floors, 3 lines)
• Modernization of vacuum pipelines for dosing dry ingredients
• Dismantling and construction works
• Installation of technological equipment and electrical works
• Bringing cable routes into compliance with hygiene standards
• Commissioning and staff training

Also, the peculiarity of this project was that S-Engineering performed, among other things, non-core work for itself: design of construction, technological parts, dismantling, installation of technological equipment, welding work, construction work. In addition, when developing the project of pipelines of liquid ingredients, S-Engineering specialists used 3D design, which allowed to make the optimal decision regarding the location of pipelines in limited space. All work on the project was correlated in advance with the periods of planned production stops, which allowed to complete all work on time.

4. In the project for configuring 10kV protection settings based on the NEPLAN software package, our specialists performed the following work:

• modeling of the network diagram of the enterprise “Mondelis Ukraine” (Trostianets);
• calculation of short-circuit currents (Short Circuit);
• coordination of protection of relay protection devices and automation for the 10 kV network and settings of circuit breakers (Selectivity Analysis);
• calculation of arc flash energy (Arc Flash study).

The arc flash calculation was performed based on the IEEE 1584 Guide for Performing Arc-Flash Hazard Calculations, which has no analogues in the regulatory framework in Ukraine. Thus, our specialists fulfilled the international requirement of the customer company on labor protection.

5. The OREO biscuit production process control system was modernized. As part of the project, Siemens Sinamics series frequency converters were installed and put into operation, which ensure high-precision, trouble-free recipe production of biscuits.

6. Another of our tasks was to combine the autonomous power plant we installed based on an internal combustion engine with a capacity of 2 MW with the plant’s power system. In addition, OBERON SE equipment using S-Engineering technology was supplied and commissioning and software development were performed.

Our specialists also performed work on modernizing the automation system of several production lines: from transporting components to baking finished products.

7. S-Engineering acted as the EPC contractor for the construction and commissioning of a 1.5 MW cogeneration plant and a 10 kV power distribution system with OBERON SE cells. This project will expand the possibilities of uninterrupted power supply to one of the factory’s production workshops. It will also allow connecting an autonomous power supply source in the form of a cogeneration plant that produces electricity and heat from natural gas.

Results

• The use of modern power supply equipment brings the level of operational safety and reliability of the factory to a completely different level. The equipment and design solutions comply with the strictest Ukrainian and European safety standards, automation and relay protection solutions guarantee a high level of trouble-free operation of the transformer substation. A high level of control over the parameters of equipment operation, accounting for electricity consumption will allow the enterprise to improve the energy resource monitoring system.
• The modernized control system of the recipe station performs the dosage of dry and liquid ingredients according to the recipe, and also allows you to prepare chocolate masses with a given ratio of components. Thus, thanks to the modernization, the explosion safety, productivity of the recipe station and, as a result, the quality of chocolate masses preparation have increased.
• In the project to adjust the 10 kV protection settings, our specialists adjusted the protection settings to minimize the arc flash and increase the safety of service personnel during the operation of electrical installations. The smaller the arc flash, the lower the class of personal protective equipment (PPE) required for operating personnel. After commissioning and final calculation of the arc flash, marking stickers with calculation data are placed on all three-phase panels of the enterprise. Based on these stickers with the indicated arc flash energy, operating personnel must wear appropriate PPE.
• The use of a switchgear with SF6 insulation has significantly reduced the space occupied by the device at the substation, and this opens up opportunities for further development of the enterprise.