Mosenergo PJSC and ROTEC Industrial Holding launch a pilot project to implement prognostics technologies at the generating capacities of the Moscow energy grid. The PRANA system will be deployed at Mosenergo CHPP-27 CCPP-450 Unit 3 by November 2017.
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 consisting of two gas turbine units GTE-160, a steam turbine, generators, two heat recovery steam generators and a booster compressor station. CHPP-27 personnel will receive analytical reports showing information on the condition of the power unit, quality of equipment starts/shutdowns and recommendations for its further operation.
Detecting malfunctions at an early stage will not only prevent accidents, but will also reduce repair and maintenance costs by at least 20% through improved procurement, logistics and periods of repair works which can now be carried out during planned maintenance. All this helps achieve a considerable increase in reliability and reduce unplanned downtime.
"Mosenergo generating facilities operate in a region with a multi-million population so reliable power supply is our key priority. The company is actively engaged in implementing best practices in the field of diagnostics of generating equipment. Prognostics is one of such technologies helping timely obtain objective information on the technical condition of power plant equipment. Its implementation will enable us to fundamentally increase reliability," said Alexander Butko, the Managing Director of Mosenergo PJSC.
"A great responsibility rests with Mosenergo: the company provides uninterruptible heat and power supply to the Russian capital. I am glad that ROTEC is also contributing to this important task: Ural steam turbines and quality servicing of gas turbines have been contributing to the reliability of the Moscow energy system for years. Today we start a new stage of our cooperation. ROTEC is bringing advanced prognostics technologies to the energy sector of the Russian capital — the PRANA system. This proven and tested tool for preventing malfunctions will now assure equipment reliability for Mosenergo," said Mikhail Lifshitz, the Chairman of ROTEC Board of Directors.
Mosenergo PJSC is the largest territorial power generation company in Russia. The company operates 15 power plants with the overall installed electric capacity of 12.9 thousand MW. The installed heat capacity of the company is 42.8 thousand Gcal/hr. Mosenergo power plants supply over 60% of power consumed in the Moscow Region and meet more than 80% of Moscow heat power demand (without considering adjacent territories). The controlling shareholder and managing company of Mosenergo PJSC is Gazprom Energoholding LLC (100% subsidiary of Gazprom PJSC).
ROTEC JSC is an industrial holding. Its core business includes gas turbine and steam turbine maintenance, power equipment manufacturing. It provides engineering services and develops a number of high technology projects across a variety of industries, in particular, the machine-building industry, energy accumulation and storage systems, prognostics and remote condition monitoring of industrial equipment.
The PRANA prognostics system builds an individual model for each particular plant. Application of predictive mathematical algorithms in data analysis allows the system to uncover defects in the parts and components of plants before they lead to a breakdown. The system automatically detects the degradation of the impeller space of the turbine and compressor, support and thrust parts of turbine and generator bearings as well as damage of burner units and instrumentation failures.
If comprehensive defects are detected in equipment, the system analyzes the parameters which are the largest contributors to the identified deviation. A specific list of such parameters is automatically determined by system algorithms. These features enable round-the-clock expert support to be organized for a large fleet of equipment.