PRANA: Industry Standard of the Future
Economic effect generated by PRANA implementation: Cutting repair costs and reducing market fines by up to 60%
Industrial IoT solution for diagnostics and predictive analytics of industrial equipment to improve equipment performance and cut operating costs.
"PRANA (Predictive Analytics) – Predictive Analytics and Remote Monitoring System – a hardware-software package that enables the identification of deviations in the functioning of industrial equipment 2–3 months before the probable fault.
The PRANA industrial IoT solution combines methods of statistical analysis – the analytical core of the system, machine-learning technologies – an archive of defect symptoms, and big data processing tools – expert modules.
To collect equipment-performance parameters, the lower level of the System is deployed at the industrial site, thereby allowing for the safe collection and transmission of the data to the Situational Center. The PRANA System analyzes the data arriving from the running equipment in real-time and automatically detects any deviations, ranking them by contribution to the emerging defect.
The PRANA industrial IoT solution combines methods of statistical analysis – the analytical core of the system, machine-learning technologies – an archive of defect symptoms, and big data processing tools – expert modules.
To collect equipment-performance parameters, the lower level of the System is deployed at the industrial site, thereby allowing for the safe collection and transmission of the data to the Situational Center. The PRANA System analyzes the data arriving from the running equipment in real-time and automatically detects any deviations, ranking them by contribution to the emerging defect.
This information is relayed to experts at the Situational Center, who generate the appropriate recommendations for the operating personnel. System-performance information and recommendations on maintaining equipment in good working order are available for customer personnel remotely and in mobile applications. Emergency alerts are sent via SMS, e-mail, phone calls and PUSH-notifications. Customers receive round-the-clock support, scheduled reports and recommendations on optimizing equipment performance and maintenance.
PRANA Economic Efficiency
Economic effect generated by the PRANA System implementation at one of Russia’s largest generating companies:
Incident count
The number of incidents in CCGT units.
Incident loss
Losses from power-unit downtime.
Reduce unscheduled shutdowns
PRANA identifies defects long before they lead to failure. All necessary repairs are carried out during scheduled shutdowns.
Cut your repair costs
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
- Mathematical Tools
- System Architecture
- Situation Center
- Our Services
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.
More details
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.
More details
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.
More details
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.
More details
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.
Rapid commissioning
Just one month is required to install the system on industrial equipment from most manufacturers without modification or additional configuration.
Versatility of PRANA
PRANA uses versatile mathematical algorithms that support any type of equipment, including turbines, engines, compressors, pumps, boilers, etc.
Largest archive of historical data
Largest archive of historical data among OEM-independent predictive analytics solutions.
News
09 April 2020
The introduction of a self-isolation regime, along with measures to prevent the rapid spread of coronavirus infection, has affected many businesses, and has brought some to a complete halt. However, IIoT solutions have revealed new opportunities for responding to the changing situation. The PRANA hardware and software complex has made it possible to minimize the negative consequences of the ongoing situation.
23 March 2020
With the spread of the coronavirus epidemic, many employers are moving their employees to remote work. Those who are not yet ready for this move must comply with government instructions, which include cancelling mass gatherings and monitoring the health of employees. Top managers and owners of Russian companies tell us how they are managing to go on working in these new conditions without reducing the efficiency of their processes.
12 February 2020
Almost three years ago, when the term “digitalization” was still perceived as a neologism in the Russian business lexicon, and the mass introduction of digital services, mainly imported ones, was just beginning in our domestic industry, the ROTEC JSC advancement – the Predictive Analytics and Remote Monitoring System PRANA – was registered in the Unified Register of Russian Programs.
03 February 2020
Mikhail Lifshitz, Chairman of the Board of Directors of ROTEC, explains why he is against solar power plants, considers the real need for the in-house manufacture of high-capacity gas turbines in Russia, and points out the mistake of Elon Musk.
21 January 2020
Russia’s Rotec and Germany-based Siemens have signed a cooperation agreement to build a unified information environment in the energy sector. The document was signed by Ivan Panasyuk, general director of Rotec JSC, and Zhanna Shalygina, director of Siemens Digital Industries in Russia.
20 January 2020
ROTEC and Siemens have signed a cooperation agreement to build a unified information environment in the energy sector. The document was signed by Ivan Panasyuk, General Director of ROTEC JSC, and Zhanna Shalygina, Director of Siemens Digital Industries in Russia.
10 January 2020
News story of the C21TV channel (Singapore) covering the Industrial Transformation ASIA-PACIFIC trade fair (ITAP-2019).
24 December 2019
RusHydro PJSC and ROTEC JSC signed a contract to introduce the PRANA predictive-analytics and remote-monitoring system at Yakutskaya SDPP-2. PRANA is to monitor and predict the technical condition of 4 General Electric LM 6000 PF DF gas turbine units, 4 Brush turbo-generators, 4 КУВ-38.1-185 heat-recovery boilers, 2 Atlas Copco TP10T22D1 gas-booster compressors and 4 unit transformers.
23 December 2019
In western Europe you may think of security of power supply in terms of keeping the regulator happy and avoiding fines. In the extreme cold of Russia and Kazakhstan says Jeremy Cowan, the focus is on saving lives by avoiding unexpected shutdowns in power generation.
We work with
History
238 accidents
have been prevented
by PRANA continuous monitoring
by PRANA continuous monitoring
3 500 000 hours
of equipment digital operating time
have been analyzed
have been analyzed
2 500 tags
are processed every second
on each power-generating unit
on each power-generating unit
PRANA in the Media
02 October 2018
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
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
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
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
