АPAVLODARENERGO JSC became the first foreign customer of the PRANA predictive analytics system and a leader in predictive analytics systems implementation in the country. The state-of-the-art technology will ensure the reliability and safety of the power generating equipment of generator-transformer unit No. 6 at CHPP-3 in the city of Pavlodar (Kazakhstan). The T-120/130-130 PR2 steam turbine manufactured by the Ural Turbine Works, and the generator and 6T TDTs-160000/110 generator transformer of Power Machines – Toshiba. High-Voltage Transformers are connected to the system. The total capacity of turbine unit No. 6 is 125 MW.
“The use of state-of-the-art solutions and developments is the basis of our technical policy. We plan to use digitalization and the implementation of smart systems to improve the economic efficiency and reliability of the equipment. After a thorough investigation of the market, we decided on the PRANA prognostics system, which had already proved to be efficient in Russian companies in the power industry,” noted Oleg Perfilov, General Director of PAVLODARENERGO JSC.
“By upgrading the fleet of steam turbines at CHPP-3 of PAVLODARENERGO JSC, Kazakhstan’s energy suppliers have de-facto confirmed their interest in the trouble-free, predictable and effective functioning of modern power generating facilities. In the conditions of competitive market, it is very important to provide reliable protection for expensive equipment, and to ensure the safety of personnel and the company in general against potential accidents and unscheduled equipment shutdowns. Our system of predictive diagnostics, which has proved its efficiency, is capable of preventing abnormal situations and saving considerable amounts of money for the customer. By equipping their energy facilities with the PRANA system, the professionals of PAVLODARENERGO JSC have established a new high standard of safety and responsibility for the entire region,” Artyom Markelov, Head of PRANA System, commented
In addition to basic energy equipment, PRANA will be used to monitor the condition of the turbine unit’s foundation. ROTEC specialists equipped the facility with an integrity monitoring system based on an acoustic emission method, as well as a set of sensors for determining temperature, deformation, tilt angle, vibration and linear displacement. Using this data, PRANA will be able at the earliest stage to detect the formation of cracks and material degradation due to vibration from the turbine unit, and to assess column deviations, as well as the smallest movements in the foundation. Data on the facility’s condition will be taken into account when analyzing the operation of the main equipment of a turbine unit, which will further increase the accuracy of forecasts and the efficiency of the solution.
The PRANA Predictive-Analytics and Remote-Monitoring System (https://prana-system.com/) is an industrial IoT solution that identifies defects in the operation of industrial equipment 2–3 months prior to possible accidents. The system combines methods of statistical analysis, digital product imaging, an instrumental technique for working with big data and machine-learning technologies.
PAVLODARENERGO JSC (http://pavlodarenergo.kz/ru/) is a vertically integrated company, including all elements of energy supply in the Pavlodar Region (generation, transmission and sale of energy resources). The company supplies electricity to the territory of the Pavlodar Region with a total area of 105,900 square kilometers and a population of 754,000 people.
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The Internet of Things (IoT) integrates devices into a computer network and allows them to collect, analyze, process and transmit data to other facilities via software, applications or technical devices
As of 2021, the PRANA hardware-software package is the first of the industrial systems for predictive analytics and remote monitoring to switch to the Russian analytical database management system Yandex ClickHouse.
Monitoring-and-diagnostics data (M&D) form the basis for determining the technical condition of high-voltage equipment and developing repair schedules for such equipment. World experience shows that from the economic standpoint, it is expedient to carry out such monitoring using the remote online monitoring of facilities. In this case, all generator assemblies can be monitored online. At present, the corresponding measuring base has been created for each component of a modern generator, which makes it possible to equip generators with sensors and systems for monitoring and diagnostics in any variation and package (in terms of control).
Predictive analytics and online IIoT surveillance systems respond to modern challenges
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.
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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.
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