Revolutionizing Power Plant O&M with Pulse Digital Twin

Reduction in unplanned downtime

Problem Statement

A global leader in power plant O&M services managing over 40 thermal power plants worldwide struggled with escalating costs driven by reliance on on-site experts and limited visibility into asset health. The absence of centralized monitoring resulted in reactive maintenance, frequent downtimes, and challenges in meeting performance standards across their geographically dispersed plants.


Objective:

The OEM aimed to revolutionize its Operations & Maintenance (O&M) services by centralizing asset monitoring, minimizing on-site interventions, and consistently meeting stringent availability and performance standards. With Pulse-Intelligent Digital Twin, the OEM sought to optimize asset utilization, predict and address maintenance needs proactively, elevate service quality, and strengthen its competitive advantage in the market.

Challenges

  • Limited Visibility: Despite its vision to transform O&M services, the OEM faced several challenges that hindered its ability to achieve seamless asset management and operational excellence:
  • Global Coverage: Managing 40+ thermal plants across multiple continents with varied asset types and operational conditions.
  • Performance Standards: Meeting strict availability criteria to ensure the reliability of critical assets like boilers, turbines, and pumps.
  • High Operational Costs: Reliance on on-site experts for diagnostics increased costs and limited operational flexibility.

 

Solutions

Pulse Intelligent Digital Twin: The OEM implemented Pulse platform, providing centralized data access and predictive asset management, including:

Centralized Remote Operating Center (ROC):

Enabled real-time monitoring and diagnostics from a single location, integrating plant data into one centralized server.

Digital Twin Library:

Leveraged a comprehensive library covering 50+ asset classes, including critical assets like boilers, turbines, and pumps.

Predictive Modeling:

Utilized machine learning algorithms to identify early warnings for potential equipment failures, reducing the likelihood of unscheduled outages.

Enhanced Diagnostics and Insights:

Real-time analytics offered prescriptive insights, empowering O&M teams to resolve issues remotely and avoid unnecessary site visits.

Impact

Pulse provided measurable benefits across the OEM’s operations, addressing core business needs:

Higher Service Levels:

Predictive alerts and diagnostics enabled swift issue resolution, minimizing downtime and enhancing asset reliability.

Reduction in Unplanned Outages:

Improved maintenance scheduling resulted in a 20% reduction in unexpected equipment failures.

Cost Optimization:

Centralized monitoring allowed for efficient deployment of expertise, reducing on-site visits and lowering overall O&M costs.

Increased Profit Margins and Efficiency:

Consolidated data insights and centralized operations boosted profit margins and elevated the overall efficiency of plant management.

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