Russian developer of innovative technologies in the field of photonics, Profotek, has completed a turnkey project to replace the current measurement system of a series of aluminum electrolysis vessels at the Kazakhstan Electrolysis Plant in Pavlodar, Kazakhstan, in five months.

The basis of the current measurement system in this project are 14 sets of electron-optical current transformers. Optical transformers are capable of measuring DC current without distortion and with high accuracy at ratings up to 400 kA, in a wide temperature range and under conditions of powerful magnetic field.

The optical transformers installed at KEZ are registered in the register of measuring instruments of Russia, as well as the Republic of Kazakhstan, and can be used at hazardous industrial facilities, be used to build technical and commercial electricity metering systems, in protection and automation systems of electrical substations and at generation facilities.

The choice of KEZ in favor of the Profotech project was not made by chance. The interaction of plant specialists and their acquaintance with optical technologies began back in 2009. At that time the company "Unique Fibre Devices", which was founded by scientists and engineers from Fryazino, supplied one of the first optical sensors developed by it to the enterprise. The device confirmed its functional characteristics, was installed at the electrolysis series and to this day performs its task by making measurements. Subsequently, at the end of 2010 a team of scientists and engineers of "UVP" received support from Rusnano foundation, which allowed to create a renewed team and a new company - JSC "Profotech" on the basis of the existing scientific competences and technologies in the field of photonics.

Extensive experience in project implementation, unique qualities of the product, cost control and balanced pricing policy, coupled with the persistence and professionalism of the employees allowed the company to win the tender, leaving behind a world-renowned corporation from Sweden at the final stage. This is not the first time that Profotech beat its notorious competitors in international tenders, which is a matter of special pride for the company.

About the project

When we were discussing the application of optical transformers for current measurements, Profotek developed a comprehensive solution for the measurement system, which was approved by KEZ specialists. The solution is a set of devices combined into a single measurement system designed to perform the following functions:

1) measurement of direct current on power bus of electrolysis shells series by electron-optical flexible current transformer TTEO-G-1-P-400000... with accuracy class 0,2;

2) measurement of direct current on 12 rails of rectifying units supplying a series of electrolysis vessels by flexible electro-optical current transformers TTEO-G-1-P-320000..., accuracy class 0.2

3) transmission of real-time information on current measurements to the main controller of current control of aluminum electrolysis series and technological process, as well as to the controllers of rectifier units

4) real-time transmission of information on current measurements to the main control board to provide operational data on the results of measurements to the dispatching personnel

5) synchronization of measuring current transformers through data acquisition and transfer device (RTU-325 RTU) of "Elster Metronika" Ltd with the plant-wide system of uniform time from NTP server to ensure the uniformity of measurements

6. data collection on current measurements - in RTU-325 SCADA, calculation and transmission of

a. current values - to SCADA (the information is displayed on the central dispatcher's panel";

b. kA×hour and diagnostic information about the state of measuring transformers - to the existing standard profile of the automated energy metering environment Alpha CENTER;

c. interval measurements of currents and unbalance - to the internal web-server.

A significant part of the project has also been taken by specialists of "Elster Metronica" of Honeywell group, whose participation has provided high-quality integration of DC measurement system into the Alfa CENTER energy metering system and into the Customer's SCADA system. The combined experience of both companies made it possible to implement a new functionality for KEZ - high-precision process energy metering and remote control of optical meters "Profotech" - within the strictly scheduled time.

The optical metering system successfully replaced an unreliable and outdated system based on Hall sensors

About the company

Currently Profotek Ltd. uses its own unique technology (know-how) to develop not only breakthrough products - electronic optical current and voltage measuring transformers but also arranges their serial production. All this was made possible thanks to the synergy of a team that brought together scientists, engineers and specialists in photonics, metrology and the electric power industry within the project. This example shows that RUSNANO's investment and the support of the Moscow government helped the company's team radically improve its technology, design, and proprietary software for the manufactured meters to an industrial stage.