Power generation in Russia: IoT predictive analytics saves lives not just profits

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. 

This isn’t just hyperbole. A huge explosion in a Russian hydro-electric power plant a few years ago caused a massive power outage and lives were lost in the cold weather as a direct result.

So it was instructive to talk to a team from ROTEC JSC recently, to hear how they have been digitalising the Russian power generating sector since 2015 and have gained some solid results. The PRANA system is already installed on 22 combined cycle generating units and combustion turbine units with capacity of more than 3.2GW all over Russia and in Kazakhstan. Connected equipment value exceeds US$4 billion.

PRANA can detect faults up to two to three months before an incident occurs. Only one month is needed to install and set up the PRANA Predictive Analytics and Remote Monitoring System on any industrial object. It is used on a wide range of equipment from various manufacturers, PRANA is independent from original equipment manufacturers (OEMs).

“In 2011 we started research into remote monitoring of power generating equipment,” says ROTEC’s Alexander Levin. “But monitoring is not enough, it is crucial to avoid unexpected shutdowns. Power companies would be heavily fined in Russia if these occurred, because it’s not just monetary losses, in the extreme cold people would die.”

ROTEC now monitors 22 plants in Russia and one in Kazakhstan. And there are other applications in the oil & gas industry. Using new acoustic emission methods, the company can monitor large pipes, storage tanks and other equipment upstream in the oil & gas supply line.

According to Maxim Lipatov, technical director of the PRANA project, “Sulzer is one of our key customers, providing services for gas turbines from various OEMs like Siemens and GE. For every unit of equipment we build a mathematical model and collect data which we compare with an ideal model. Temperatures, oil and fuel pressures, and other crucial information is coming live from Russian plants 24/7. So, if something is wrong, our experts can tell what action to take.”

Maxim Lipatov, ROTEC: Enterprises are now transparent.

Lipatov showed your correspondent a tablet carrying live data feeds from power generation clients. On one screen were the 10 most important system discrepancies. “We can see it may be a defect or perhaps a degradation of a system. Engineers can have time to plan maintenance work, and so save a lot of money,” says Lipatov. “If you are an equipment owner you can see the status continuously, all parameters and data are logged and it shows how people react to your alarms. Therefore, enterprises are now transparent. We have over 300 models, they are all unique for every turbine, compressor and boiler.”

“We are independent from the OEMs and more objective,” adds Levin. “Our system unites all the different manufacturers’ equipment.” And, as the slide above shows, ROTEC works with diverse equipment […]

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