PRANA: Predictive Analytics and Remote Monitoring System

Early detection of defects not only helps to avoid accidents, but also to plan in advance the purchase of spare parts, streamline logistics, and reduce the inventory.

Monitor personnel and equipment

Assess the quality of work performed by personnel and contractors, monitor compliance with the terms and rules for operating equipment. Plan your costs and capacity utilization in real time.

Identify the causes of accidents

By analyzing historical data you can identify the causes of an incident and assess whether the actions taken by personnel and the behavior of equipment were correct.

Industry Solutions

Energetics

Gas turbines
Steam turbines
Gas compressor booster stations
Generators
Transformers
Boilers
Gas piston machines
Pumps
Water treatment system

Industry Solutions

Chemical industry

Oil exchange columns
Agitators
Dynamic mixers
Pumps
Transformers
Compressors
Fans

Industry Solutions

Oil and gas industry

Pressure vessels
Heat exchangers
Coke chambers
Reactors
Pipelines
Spherical tanks
Vertical steel tanks

The system's operating principles

PRANA is based on the Multivariate State Estimation Technique (MSET).

An equipment model is created and configured using historical data. Behavioral abnormalities are detected using a single integrated T² criterion and parameter imbalances, which are ranked automatically based on their contribution to the abnormalities. This approach has been developed specifically for monitoring equipment at nuclear power plants, where the reliability of equipment is considered to be the highest priority.

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The MSET (Multivariate State Estimation Technique) core is needed to create and play multidimensional models of the equipment state.

Playing models based on actual operational data makes it possible to identify deviating parameters in the operation of industrial equipment with extremely high sensitivity. This is the case even if they do not yet affect the state of the installation, which means they are not recorded by traditional control and monitoring systems.

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The Situation Monitoring Center provides 24/7 facility monitoring.

The dispatcher is alerted at the slightest deviation. The system automatically identifies the location and time of the incident.

Deviations are reported to the Expert Analysis Center, where the experts prepare their conclusion based on automatically generated recommendations for equipment maintenance.

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The ROTEC Situation Center provides remote monitoring and predictive analytics of industrial equipment.

The Center's team includes experts with many years of experience in both science and practical work in the area of vibration diagnostics and vibration adjustment, turbine, compressor, boiler, thermal and electrical equipment.

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Benefits

Approved by insurance companies

PRANA is used to investigate incidents in the Russian energy sector. A major Russian insurance company considers the use of PRANA when calculating its insurance rate.

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Rapid commissioning

Just one month is required to install the system on industrial equipment from most manufacturers without modification or additional configuration.

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Versatility of PRANA

PRANA uses versatile mathematical algorithms that support any type of equipment, including turbines, engines, compressors, pumps, boilers, etc.

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Largest archive of historical data

Largest archive of historical data among OEM-independent predictive analytics solutions.

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News

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13 November 2018

New features of the PRANA prognostics system simplify working with big data

The state Register of computer programs includes the new program modules of the PRANA prognostic system. They are intended to emulate possible accidents and malfunctions, to automate technical reporting, and also to automatically update digital models after repair or service of the equipment.

26 October 2018

Gas turbines of the three major manufacturers have been connected to the PRANA prognostics system

ROTEC specialists successfully connected two Alstom GT13E2 gas turbines operated at Novogorkovskaya CHPP of PJSC T Plus to the PRANA prognostics system. The total capacity of the equipment is 360 MW. The PRANA mathematical model monitors and every second updates 344 operating parameters of the connected Alstom turbines.

29 August 2018

UTW turbines and PRANA prognostics system will ensure reliable operation of new digital power units of Kazan TPP-1

Two 230 MW combined-cycle power plants were commissioned at Kazan TPP-1 (Tatenergo, JSC). These are the Russia’s first power units initially connected to a Russian equipment-status prognostics system.

31 May 2018

Representatives of Belenergo Learn About ROTEC’s Prognostic Technologies

The Belarusian colleagues studied the functional characteristics of the prognostic equipment for PRANA power devices. The new equipment has been designed and patented by ROTEC JSC . The company staff showed differences between the new system and the traditional monitoring systems installed by manufacturers of power equipment on their machinery.

23 May 2018

UTW digitalised steam turbine to ensure efficient and smooth waste processing

Ural Turbine Works (ROTEC Holding) has developed Russia’s first turbine for waste incineration plants — Kp-77-6,8. This makes it possible to abandon the use of expensive equipment from foreign producers in favour of domestic technologies. Furthermore, due to the use of ROTEC Holding’s prognostic technologies, the new turbine now has the highest level of reliability.

22 May 2018

AlfaStrakhovanie and ROTEC begin cooperation in the field of technological risk forecasting

AlfaStrakhovanie and ROTEC have signed an agreement on cooperation in the field of technological risk forecasting and insurance. The companies have agreed on the possibility of using the PRANA industrial equipment condition prognostics system for retrospective analysis of incidents which have led to the occurrence of insured events.

23 August 2017

Mosenergo CHPP-27 Deploys PRANA Prognostics System

The pilot project is aimed at detecting possible equipment malfunctions at the early stage of their inception — 2-3 months before such a potential malfunction occurs. The system will analyze data on the condition of the main equipment of the CCPP-450 unit.

10 July 2017

Mikhail Lifshitz, Chairman of the Board of Directors, at ROTEC, showed Vladimir Putin the new power industry technologies that have been developed for the country

The International Industrial Fair Innoprom-2017 began with a visit by the Russian President Vladimir Putin. Mikhail Lifshitz, Chairman of the Board of Directors, at ROTEC, told the President about the PRANA System used for prognostics and monitoring of the condition of industrial equipment, new turbines for Moscow and nuclear-powered icebreakers made by the Ural Turbine Works (UTW), about TEEMP's supercapacitors, projects of the T Plus Company and the Kamensk-Uralsky Non-Ferrous Metal Working Plant.

16 June 2017

PRANA project was presented to participants of the Russian Oil and Gas IT summit "Digital Oil Field"

Maxim Lipatov, Chief Specialist of ROTEC Monitoring and Forecasting Department, spoke during the panel discussion called "Management of Resources and Fixed Assets" of the IT summit "Digital Oil Field", where he described the PRANA system of prognostics and monitoring of the condition of industrial equipment.

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History

238 accidents

have been prevented
by PRANA continuous monitoring

3 500 000 hours

of equipment digital operating time
have been analyzed

2 500 tags

are processed every second
on each power-generating unit

All locations

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PRANA in the Media

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02 October 2018

Experts united in one network

Surprisingly, there was no existing specialized system for industrial experts to work remotely and in collaboration until now. Let's be honest - using e-mail to jointly search for defects in a gas turbine is as effective as hammering a nail with foam rubber. But the situation is changing.

Source: eprussia.ru

27 September 2018

Predictive analytics for power transformers

The natural desire of the owner of a technical facility, as a business unit, is to find out the minimum financial investment needed to ensure the equipment is in operable condition, and as a result, receive the maximum profit during operation of the facility. To do this, up-to-date and accurate information must be obtained on how the facility is operated.

Source: energyexpert.ru

24 May 2018

Industrial Internet for black box

Based on its own algorithms, ROTEC has developed a remote monitoring and prognostics system for power equipment. The main idea is not so much to track the operating parameters of a rotary machine - many manufacturers are able to do this - but to obtain an advance and accurate prediction of its future state

Source: stimul.online

02 February 2017

Interview with Mikhail Lifshitz: Predict to Prevent

PRANA is an innovative tool that helps prevent machinery related accidents. This new prognostic tool allows for timely response to faults and failures of various kinds of equipment thus increasing its reliability and maintainability.

Source: eprussia.ru

PRANA: Industry Standard of the Future

Economic effect generated by PRANA implementation: Cutting repair costs and reducing market fines by up to 60%

Reduce unscheduled shutdowns

Cut your repair costs

Monitor personnel and equipment

Identify the causes of accidents

PRANA is based on the Multivariate State Estimation Technique (MSET).

The MSET (Multivariate State Estimation Technique) core is needed to create and play multidimensional models of the equipment state.

The Situation Monitoring Center provides 24/7 facility monitoring.

The ROTEC Situation Center provides remote monitoring and predictive analytics of industrial equipment.

We work with