Skip to main content

Industrial reporting and analytics based on TechnoDoc

Projects

The SMS-Automation group of companies has developed and implemented solutions for consolidating reporting data and automating document formation processes at industrial enterprises.

Download PDF with report examples

AvtoVAZ

For JSC "AVTOVAZ" the following reports have been developed and implemented:

  • Monitoring and calculation of OEE indicators for Welding, Assembly, Painting productions.
  • Calculation of SSAR (Scheduled Sequence Achievement Ratio), STAR (Scheduled Time Achievement Ratio), D-STAR (Delivery Scheduled Time Achievement Ratio) indicators.

RGU production indicator

RGU production indicator

Compliance with planned production sequence

* reports contain sample data

Rybinsk and Uglich HPPs

For the сascade of гpper Volga HPPs, an automated switching form system based on the TechnoDoc was developed and implemented. The system provides the following features to operational personnel:

  • Import of existing standard switching forms.
  • Creation and editing of new switching form templates.
  • Automation of readiness condition checks for switching form execution.
  • Automation of switching form operations execution.
  • Execution of the switching form in player mode.
  • Working with alarms and warnings.

Passing a standard switching form

Switching form designer

Selecting parameters for switching operation automation

* reports contain sample data

Sayano-Shushenskaya HPP

Sayano-Shushenskaya HPP is located on the Yenisei River near the village of Cheremushki in the Republic of Khakassia. It is the most powerful hydropower plant in Russia and one of the most powerful in the world. The installed capacity of Sayano-Shushenskaya HPP is 6400 MW, with an average annual output of 24 billion kWh. The HPP building houses 10 hydroelectric units with radial-axial turbines, each with a capacity of 640 MW.

Solutions

The upper level of the automated process control system is designed to optimize the operation of the main and auxiliary process equipment and to create a technological basis through the automation of equipment and the introduction of monitoring and diagnostic systems.

Thanks to the software package, system users have the ability to generate about 100 different reports, namely:

  • Water regime:
    • Water regime (month/day)
    • Water release log
    • Reservoir mode (month/year)
    • Kyzyl - post mark 615.5m
    • Air temperature
    • Hydrometeorological
  • Hydroelectric units:
    • Work statement of GA1, GA2, T1-GA9, GA10, T5
    • Work statement of GA MHP
    • Final report on the condition of GA MHP (month/week/day)
    • Final report on the condition of GA SSHPP (month/week/day)
    • GA efficiency
    • GA1-GA10 operation report
    • GA1-GA10 status summary during start/stop
    • Daily temperature control statement of GA1-GA10
    • Calculation of equipment readiness coefficient
  • Operational information:
    • Emergency Ministry report
    • NSS report
    • Press report
    • Lengidroproject report
    • Appendix 63 SSHPP
  • Signaling:
    • Analytical signaling report for the month/day
    • Signaling statistics
    • Daily signal statement
    • Daily statement of unique signals
  • Operating time:
    • Operating time diagram
    • Operating zones of GA for the year/month
    • Operating modes of GA for the year/month/day
    • Starts and stops of GA year/month
    • Report on the number of transitions through zone 2 (prohibited)
    • Report on the number of transitions through zones
  • Remaining resource:
    • Current journal during commutations
    • Remaining resource of switches
    • Remaining resource of GA
    • Remaining resource of transformers
    • Number of switch on/off operations at the station (month/day)
  • Electricity:
    • Electricity balance (day)
    • Electricity balance SSHPP/MHP (day)
    • Generation
    • GIS220
    • GIS500
    • Load (month/day)
    • PBR
    • Reactive consumption
    • Consumption for own needs
    • KIUM calculation
    • Daily production statement
    • Electricity (month)
    • MHP energy parameters (Moscow/local time)
    • SSHPP energy parameters (Moscow/local time).

Calculation of equipment readiness coefficient

Final report on the condition of hydroelectric units

Electricity balance (day)

GA efficiency

* reports contain sample data

Kamskaya HPP

Kamskaya HPP is located on the Kama River in the Perm region, in the city of Perm. The installed capacity of Kamskaya HPP is 552 MW, with an average annual output of 1710 million kWh. The HPP building houses 23 hydroelectric units with Kaplan turbines, each with a capacity of 24 MW.

Solutions

The upper level of the automated process control system is designed to optimize the operation of the main and auxiliary process equipment and to create a technological basis through the automation of equipment and the introduction of monitoring and diagnostic systems.

Thanks to the software package, the user can generate the following reports:

  • Daily statement
  • Water release log
  • HPP monthly work statement
  • VEP-month
  • Electricity balance
    • Oil levels in MNU tanks
    • Oil levels in GA pivot bearing baths
    • Crosshead vibration and GA shaft runout
  • Piezometers
  • GTS diagnostics
    • Operating time diagram
    • GA operating zones for the year/month
    • GA operating modes for the year/month/day
    • GA starts and stops year/month
  • Measurement logs – month
    • Cementation gallery
    • Drainage gallery
    • Inspection gallery
    • Lower tailrace piers

    Mimic diagram

    Daily statement

    Monthly measurement logs

    HPP work indicators statement

    * reports contain sample data

    Middle Volga Transnefteproduct

    JSC "Middle Volga Transnefteproduct" is a division of JSC "Transnefteproduct" engaged in the transportation of petroleum products through main pipelines. The useful capacity of the tank farm is 43,576 thousand m3. The length of the pipelines is 1,287.82 km with six pumping stations and one loading point at the airport. The pipelines run through the territories of the Republic of Tatarstan, the Republic of Chuvashia, and the Nizhny Novgorod region.

    Solutions

    The goal of creating the SDCS for the transportation of petroleum products through the Moscow-TDP Kazan main pipelines is to effectively and fully ensure dispatch control and automated management of all existing technological facilities, data collection on their condition, and the receipt of all necessary reporting documents.

    The reporting module is designed to create templates and generate reports on the progress of the technological process based on the archive of operational data and data from external systems. SDCS users can generate the following reports:

    • ASU TP – Equipment malfunction
    • ASU TP – Cathodic protection status
    • ASU TP – Telemechanics equipment status
    • Security – user logins/logouts
    • Security – user actions
    • Security – system settings changes
    • Security – audit data deletion
    • KPD SOT pressure
    • KNP – Deviation from normative parameters
    • Product pipeline – Almetyevsk – Nizhny Novgorod
    • Product pipeline – Nizhnekamsk – Almetyevsk
    • Product pipeline – Nizhnekamsk2 – Almetyevsk
    • Almetyevsk RP
    • Almetyevsk RP measurements for 2 hours
    • Almetyevsk RP summary by product types
    • SIKN Taif-NK – TDP Kazan 2-hour report
    • SIKN Taif-NK – TDP Kazan daily report
    • SIKN Taneko – TDP Kazan 2-hour report

    Product pipeline - Nizhnekamsk2 - Almetyevsk

    Almetyevsk RP

    ASU TP - Telemechanics equipment status

    SIKN Taif-NK - TDP Kazan 2-hour report

    * reports contain sample data

    Zhigulevskaya HPP

    Zhigulevskaya HPP is located on the Volga River in the Samara region, in the city of Zhigulevsk. It is the second most powerful hydroelectric power plant in Europe. The installed capacity of the power plant is 2404 MW, with a design average annual electricity production of 10,900 million kWh. The HPP building houses 20 vertical hydroelectric units with Kaplan turbines: 8 with a capacity of 115 MW each, 8 with a capacity of 125.5 MW, and 4 with a capacity of 120 MW.

    Solutions

    The goal of the ASU TP of Zhigulevskaya HPP is to increase objectivity and improve the quality of control and management of the technological process of the station through the use of equipment monitoring, a visual problem-oriented user interface, and computer generation and storage of technological documents.

    The following reports are generated at Zhigulevskaya HPP:

    • Number of GA starts/stops
    • Operating time by operating zones
    • Operating time by operating modes

    Mimic diagram

    Operating time diagram

    GA statement

    Hydroelectric unit operating time

    * reports contain sample data

    Yegorlykskaya HPP 2

    Yegorlykskaya HPP-2 is a hydroelectric power plant on the Yegorlyk River, near the village of Levoegorlyksky in the Izobilnensky district of the Stavropol Territory. The capacity of the HPP is 14.2 MW, with an average annual output of 55.1 million kWh. The HPP building houses 4 hydroelectric units with radial-axial turbines, each with a capacity of 3.55 MW.

    Solutions

    The goal of the ASU TP of Yegorlykskaya HPP-2 is to increase objectivity and improve the quality of control and management of the technological process of the station through the use of equipment monitoring, a visual problem-oriented user interface, and computer generation and storage of technological documents.

    The following reports are generated at Yegorlykskaya HPP-2:

    • Number of GA starts/stops
    • Operating time by operating zones
    • Operating time by operating modes

    Mimic diagram

    Operating time diagram

    GA statement

    Hydroelectric unit operating time

    * reports contain sample data

    Zaragiyskaya MHP

    Zaragiyskaya MHP is an under-construction hydroelectric power plant on the Cherek River, near the village of Aushiger in the Cherek district of Kabardino-Balkaria. Structurally, Zaragiyskaya HPP is a typical diversion power plant with a non-pressure water supply in the form of a channel. A feature of the station is the absence of a dam - water is taken directly from the discharge channel of Aushiger HPP. The installed capacity of the HPP is 30.6 MW, with an average annual electricity production of 114 million kWh.

    Solutions

    The control and monitoring systems included in the ASU TP of Zaragiyskaya MHP are designed to automate the equipment of Zaragiyskaya MHP to ensure the station operates in automatic and automated modes in accordance with the technological process.

    Water regime

    Operating time diagram

    Daily statement

    * reports contain sample data

    Nizhny Novgorod HPP

    Nizhny Novgorod HPP is a hydroelectric power plant on the Volga River near the city of Zavolzhye in the Gorodetsky district of the Nizhny Novgorod region. The station is part of the Volga hydroelectric power cascade, representing its fourth stage. The HPP's dam system, with a total length of 18.6 km, is the longest among the dams of hydroelectric power plants in Russia.

    The station houses eight hydroelectric units, seven of which have a capacity of 65 MW, and one - 68 MW. The hydroelectric units consist of Kaplan turbines PL 510-VB-900, operating at a design head of 14 m (maximum head - 17.5 m), and vertical synchronous generators SV 1340/155-96. The turbines are four-bladed, with a runner diameter of 9 m and a maximum flow through the flow part of 500 m³/s. The generators have a maximum capacity of 80 MW, but the available capacity is limited by the turbine's capabilities and is 65-68 MW.

    Solutions

    Increasing the efficiency of operational and dispatch personnel in performing switching operations in electrical installations. The system allows for control of switching operations in manual and automated modes. The system also includes a visual designer for switching form templates, allowing for the creation of new forms based on standard templates.

    Switching form designer

    Working with switching forms

    * reports contain sample data

    Kuban HPP 2

    HPP-2 is located in the Prikubansky district of the Karachay-Cherkess Republic at the 76th kilometer of the Great Stavropol Canal, with a peak operating mode according to the established schedule. HPP is a diversion, surface-type plant with a total capacity of 180 m3/s and with individual pressure pipelines supplying water to each unit.

    The capacity of the HPP is 184 MW, with an average annual output of 582.2 million kWh. The HPP building houses 4 radial-axial hydroelectric units RO170/638aVM-250, each with a capacity of 46 MW, operating at a design head of 118.4 m.

    Solutions

    Increasing the efficiency of operational management and bringing it in line with the technological safety requirements for the operation of hydro turbines by registering and controlling the technological indicators of the hydro units' operating modes in accordance with the requirements of Operational Instruction No. 8 (OU-08-2014 (TP) "On the organization of automatic registration of technological indicators of hydro units' operating modes" PJSC "RusHydro").

    Continuous automatic monitoring and registration of the following indicators are provided on all HPP-2 hydro units:

    • Number of starts and stops.
    • Operating time in generator idle mode, turbine idle mode.
    • Operating time in non-recommended and prohibited zones.
    • Number of entries and exits in non-recommended and prohibited zones.
    • Number of cycles of transitions through the boundaries of the prohibited zone.
    • All indicators are accounted for over the following periods: from the start of operation, from the start of operation after the last major overhaul, from the beginning of the current year, from the beginning of the current day, from another period set by the hydro turbine manufacturer.

    Diagram

    Hydro unit parameter archive

    * reports contain sample data

    Volzhsky Automobile Plant CHPP

    The Volzhsky Automobile Plant CHPP (CHPP VAZ) is an energy enterprise in the city of Tolyatti, Samara region. The installed electrical capacity is 1172 MW. The installed thermal capacity is 3903 Gcal/h. The plant produces up to 40 percent of the electrical and 30 percent of the thermal energy produced in the Samara region, providing energy supply, heating, and hot water supply to all divisions of OJSC AVTOVAZ, the Avtozavodsky district of Tolyatti, and enterprises in the industrial and communal zone of the city.

    Solutions

    The purpose of the system is to provide personnel of the station's chemical shop with the ability to efficiently and fully control the condition of water treatment and thermal energy equipment, as well as the quality and composition of water. The system allows for monitoring the main indicators of the technological process and keeping logs of equipment operation. The system was implemented as part of the technical re-equipment of the automated control system of the CHPP VAZ chemical shop to ensure satisfactory technical condition of the equipment for the accident-free passage of the autumn-winter period 2017-2018.

    The following daily reports are generated at CHPP VAZ:

    • Washing water tank log
    • Additional equipment log
    • Raw and clarified water log
    • NPTS logs
    • Coal filter and condensate cleaning log
    • UPTS BPTS logs
    • Chemical shop log

    Main menu

    Daily equipment log

    Chemical shop

    * reports contain sample data

    John Deere Rus

    The system is developed for a factory producing agricultural seeding and tillage equipment. Currently, the factory performs such production processes as metalworking, welding, painting, and assembly of equipment.

    Solutions

    The information system is designed to analyze the performance of the paint line for components and assembly production parts by determining the location of trolleys with parts for painting in various sections of the paint line and measuring the time trolleys spend in these sections.

    The system allows monitoring the current state of the paint line conveyor, provides the ability for slingers to transfer parts from an order to a trolley for further painting, for the inspector to accept painted parts, send parts for repair, or remove parts from repair to further provide data for report generation.

    The reporting subsystem provides an opportunity for interested factory personnel to track the volumes of painted parts and materials used, receive timely information about the load and productivity of the paint line, and determine the need for workers and equipment in accordance with the company's work schedule.

    The factory provides for the generation of the following reports in the TechnoDoc PC:

    • Paint line load
    • Staffing recommendations
    • Overall equipment effectiveness (OEE)
    • Brief report on repair part costs
    • Detailed report on repair part costs
    • Work section status

    Slinger's workstation

    Loading parts

    Unloading parts

    Inspector's workstation

    Paint line load

    Overall equipment effectiveness (OEE)

    Repair part costs

    * reports contain sample data