Maximize Steam Turbine Efficiency with Pulse Intelligent Digital Twin

Upto 20% Reduction in Downtime

Upto 2% Efficiency Boost

Problem Statement:

A steam turbine OEM faced significant challenges with their industrial turbines, including frequent downtimes, unnoticed wear and tear, and inefficient operations. The reliance on traditional reactive maintenance methods led to high costs, unplanned outages, and difficulty in maintaining performance standards under fluctuating loads and mechanical stress.


Objective:

The goal was to enable the steam turbine OEM to deliver superior value to their customers by transitioning from reactive to proactive maintenance strategies. The focus was on enhancing turbine performance, minimizing unplanned downtimes, and extending equipment lifespan through real-time data integration and predictive analytics. This approach aimed to strengthen OEMs' aftermarket services, improve customer satisfaction, and unlock new revenue opportunities.

Challenges

  • Frequent Downtime: Unplanned outages disrupted energy output and increased operational costs.
  • Mechanical Stress: Vibrations, bearing wear, and temperature fluctuations often went unnoticed until they caused major disruptions.
  • Complex Failures: High-stress operating conditions led to premature wear on critical components like blades and rotors.

Solution:

Pulse Intelligent Digital Twin provided an advanced AI-driven solution to address these challenges.

Real-Time Monitoring:

Seamless integration with turbine data to monitor critical parameters like temperature, pressure, and vibration.

Predictive Maintenance:

Early detection of issues like blade erosion or rotor imbalance to prevent costly breakdowns.

Performance Optimization:

Actionable insights for precise adjustments to maintain peak efficiency across variable loads.

Impact

Upto 20% Reduction in Downtime:

Early issue detection reduced unplanned outages.

Upto 2% Efficiency Boost:

Optimized heat rates lowered energy costs and improved output.

Extended Equipment Life:

Predictive maintenance prevented wear and tear, increasing turbine longevity.

Cost Savings:

Targeted maintenance focused on high-risk components, reducing overall expenses.

Boost Turbine Efficiency and Reliability

Leverage Pulse’s Intelligent Digital Twin solution to unlock your turbines' full potential. Contact us today!

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