"Electronmash": course on innovation

–  What is the situation with import substitution in the field of equipment for electrical networks?

The market for Russian equipment in relay protection, automation, telecommunications, as well as measuring instruments and metering devices, offers a sufficient number of modern solutions. Power equipment operating at voltages of 6-110 kV is also represented by Russian manufacturers with high-quality products. Therefore, as a manufacturer of 6-35 kV switchgear and 6-35-110 kV transformer substations, we do not face issues with Russian components. However, surprisingly, there are no fully competitive solutions in the field of power equipment at 0.4 kV. The perception that 0.4 kV equipment is inherently simple is quite misleading. A complete range of power switching equipment at 0.4 kV must meet high standards regarding weight, dimensions, operational, and functional characteristics. Modern trends in the production of this equipment imply increased reliability, reduced dimensions while maintaining load and switching capacity, expanded requirements for monitoring capabilities, and new functional requirements in the context of developing automated control systems and enhancing energy efficiency within the frameworks of "smart energy" and "smart technology." Thus, 0.4 kV power switching equipment is a distinct, complex, and knowledge-intensive field. Currently, Russian-made 0.4 kV power switching equipment lags behind imported products in terms of nomenclature and nominal parameters. Practically no Russian manufacturer offers complete product lines that can replace those of global leaders (ABB, Schneider Electric, Siemens).

–  How does this situation affect you as a manufacturer of 0.4 kV electrical panel products?

It affects us significantly. Primarily, it prevents full import substitution of components due to the lack of equipment lines with the required specifications and characteristics, for which there would be a range of accessories to support "smart energy" and "smart technology" based on modern reliable solutions. Our factory is undoubtedly interested in developing solutions based on domestically produced equipment to ensure a competitive offering in the electrical engineering market. To this end, we continually analyze Russian equipment in the context of meeting the requirements set by our major corporate customers, such as Gazprom, Gazprom Neft, Lukoil, and others. We conduct special testing of equipment in collaboration with customers and gather statistics on operational experience. Both our specialists and our customers note that despite the economic attractiveness of Russian 0.4 kV switching equipment, its quality and functionality significantly lag behind those of international industry leaders.

–  Perhaps this situation requires the involvement of foreign companies in creating joint ventures? How significant is the role of the Russian side in this process? Do you see the potential for creating joint ventures with a high degree of product localization, as opposed to mere assembly operations?

The Russian side currently has limited influence over the establishment of full-fledged joint ventures. This is more a matter of foreign manufacturers' interest in maintaining and expanding their share of the Russian market. If foreign companies show interest, localizing the production of imported equipment in Russia is possible. This would essentially involve setting up production facilities for specific product lines under the management of an international company, similar to the path China has taken. Theoretically, this is possible if, for example, an international company acquires a relevant Russian enterprise or establishes a new one under a registered subsidiary in Russia, launching production using domestic materials but according to their technology. Otherwise, localization will remain at the level of simple assembly. This is evident in several cases where rebranded Asian products or devices assembled from imported components are presented as domestic equipment. There is also a high likelihood of localizing the production of predominantly outdated, budget devices with reduced functionality or consumer-grade equipment. This situation is partly due to international companies' reluctance to share their engineering developments and technologies, which constitute their core competencies, with competitors and outsourcing firms, influenced by the network organizational structure of production. For the localization of international companies' production in Russia, political decisions must be made, such as tax incentives, subsidies for launching production, and increased import duties on competitive products.

–  What prevents Russian enterprises specializing in the production of 0.4 kV power switching equipment from offering competitive solutions?

The high cost of developing and mastering such production is a significant barrier. This is due to the extensive testing requirements, the volume of research and design developments, and the costs of machinery and equipment. The substantial initial costs stem from a long period of stagnation in the industry for 0.4 kV power switching equipment and the accompanying lag in related fields, such as electrical engineering materials science, microelectronics, and others. There is a pronounced shortage of qualified engineering personnel in this area. The problem is exacerbated by patenting issues, as the most effective technical solutions have already been patented by international manufacturers, forcing Russian developers to invest significant resources in finding alternative solutions.

–  In other words, are the Russian authorities' plans to achieve a 90 percent share of domestic products through import substitution and localization utopian?

These plans currently lack a solid material foundation. Stricter requirements for the percentage of Russian and localized equipment in finished products will likely lead to a decline in market volume for key international manufacturers. However, it is important to understand that this will result in a drop in quality and functionality of the end products. Without additional measures to support domestic production and ensure foreign companies' interest in establishing local manufacturing, tightening requirements will not lead to genuine import substitution. Now it is clear that, given all the aforementioned issues, the process of import substitution in the field of 0.4 kV power switching equipment will take a long time and require significant resource investments from all stakeholders.

– A decision to create a National Association of Testing Centers based at the Federal Testing Center of Rosseti was made this year. What do you think this measure will provide for Russian manufacturers?

As a major manufacturer of electrical equipment with substantial experience supplying products to both the Russian market and the CIS countries, as well as internationally, "Electronmash" recognizes the importance of this project and is primarily interested in the establishment of the National Association of Testing Centers. Currently, when supplying to foreign markets, we are compelled to undergo additional certification procedures in the destination country or in international certification centers, as the internal Russian testing protocols are unfortunately not recognized abroad. Such costs add to the price of the final product, thereby reducing our competitiveness in international markets. The activities of the national association of testing centers, in collaboration with the Technical Committee for Standardization "Electric Power" (TC-016), aimed at optimizing and harmonizing parameters and requirements for electrical equipment with global standards, will enable us to supply equipment not only to domestic markets but also to expand our work with international EPC contractors who utilize our equipment in critical projects in Russia and are considering our products for external markets.

–  Will such an association help solve the problem of questionable origin and low-quality domestic and imported products?

We hope that the national association will be able to develop common "transparent" requirements and methodologies for product verification in a relatively short time, allowing for unified testing to meet both domestic and international standards (GOST R, IEC, IEEE, GB). However, all of this will be successful only if the national association of testing centers ensures compliance with uniform requirements by all testing centers within the association and strictly monitors these quality standards. Such activities will help address the issue of questionable origin and low-quality domestic and imported products, safeguarding our energy sector from equipment that does not meet declared requirements. Ultimately, this comprehensive set of measures will contribute to improving the level of domestic energy production.

–  Energy companies have been facing frequent natural surprises in recent years: cyclones, typhoons, ice storms, and more. What solutions does your company offer to protect network facilities from natural disasters?

We are well acquainted with working in harsh climatic conditions; a significant part of our customers are electric grid companies and the oil and gas sector, with facilities located in the northern latitudes of Western and Eastern Siberia and the Far East of Russia. Therefore, our company pays great attention to developing technical solutions that protect network facilities and operational personnel from natural disasters or, at the very least, significantly reduce their impact.

We have developed a series of complete transformer substations PS-ELM-35/10 (6) kV to operate in such conditions. We moved away from traditional substations with outdoor switchgears  at 35 kV in favor of substations with indoor switchgears, which mitigate or completely avoid the effects of natural factors. The indoor switchgear at 35 kV and 10 (6) kV from "Electronmash" JSC are quickly deployable modular buildings with a high degree of factory readiness, equipped with integrated switchgears "Eltema" and "Eltema +" along with all necessary life support systems: heating, lighting, ventilation, fire alarm, and others as required by the customer.

They withstand seismic activity up to 9 points on the MSK scale, protect equipment from precipitation, wind, and snow loads, and can be operated at temperatures as low as -60 °C. All our modifications of medium voltage switchgears used for producing PS 35/10 (6) kV include fully motorized versions and can be equipped with a system for internal monitoring of grounding status and a cassette-retractable element with a switch, as well as a system for monitoring the temperature of busbar connections. The relay compartment is designed not only for the relay protection and automation module but also for a complete distributed control system for the cell: a connection controller that manages the switch, the assette-retractable element drive, and the grounding system, collects the main states of the medium voltage switchgear, ensures necessary lockouts, and transmits data to the SCADA system (automated process control system) of the PS.

Thus, the complete compliance of our manufactured transformer substations with the requirements for next-generation substations ensures the primary goal of creating such substations: a significant reduction in operational and maintenance requirements, remote management from a dispatch point and network service center, transitioning to operations without a permanent on-site staff, and planning and conducting repairs based on the actual condition of the equipment. Our substations not only meet all technical regulations set by our customers but also fully comply with the standards of the System Operator of the Unified Energy System regarding switching operations in electrical installations. In this solution, the switching equipment such as measuring transformers,  busbar systems and other components is housed within the cabinets of the medium voltage switchgears and is reliably protected from all external environmental factors, not only by the cabinet’s resistance to mechanical and corrosive impacts but also by the building of the indoor switchgears. Therefore, the operation of equipment equipped with all modern digital systems occurs in comfortable conditions within a heated facility — switching is conducted remotely through operational dispatch management channels without the need for personnel to be present on-site. These are the solutions we propose for protecting network facilities from natural disasters.

–  One of the key "energy" solutions of autumn 2016 was the approval of the roadmap for "smart" energy. How significant is this decision for the Russian electric grid complex and for manufacturers and developers who have the chance to participate in this project?

Undoubtedly, the existence of such a roadmap and, in general, such an initiative from the Russian government is a very important decision not only for the electric grid complex of the Russian Federation but also for us as manufacturers of modern Russian electrical equipment. The Ministry of Energy of the Russian Federation, in the EnergyNet roadmap as part of the National Technological Initiative, envisions the creation of digital energy networks. From our perspective as a manufacturing plant with the necessary equipment portfolio, we will have the opportunity to supply this equipment rather than merely discussing and developing it. Currently, our consumers view developments in digital substations more as a concept for the future, but with the approval of the roadmap, specific timelines and methods for implementation will be defined, along with the development of national standardization documents and other regulatory and technical acts for the functioning of integrated systems and services in "smart" energy. As part of the development of "smart" energy, we are currently working on comprehensive solutions for digital substations and digital networks at medium and low voltages, as well as energy infrastructure for industrial enterprises, and we are developing electrical equipment for use in renewable energy generation projects. We have already begun producing equipment for a 35 MW wind power station in the Ulyanovsk region and are actively working on engineering solutions for several solar generation projects.

–  Do you believe the expectations of industry leadership regarding these plans will be justified?

Time will tell. However, the technical innovations already operational in the industry, as reported by our clients, indicate that they are serious and long-lasting. The industry has been moving toward this initiative for a long time. The first signs were evident in the documents of "FSK EES" JSC in January 2004, which outlined "General Technical Requirements for New Generation Substations of 330-750 kV." The understanding of the need for technical innovations and their application principles was subsequently reflected in "Unified Technical Policy of Rosseti" in 2013 and logically continued within the framework of the National Technological Initiative. We closely monitor all innovative requirements and feedback from our clients, focusing on improving our equipment and technical solutions. This ensures that our electrical equipment meets high operational characteristics and is aligned not only with current but also future demands.

– What problems can "smart" energy solve for network companies?

In our opinion, the digital energy network proposed for implementation under the National Technological Initiative, consisting of intelligent switching devices, energy management and accounting systems, and operational dispatch management, will enable network companies to reduce the total cost of ownership of the network, lower losses, decrease accident rates, and shorten recovery times after technological incidents. The implementation of distributed generation, controllable load consumers, and energy storage will help reduce costs associated with creating and maintaining reserves.