Fuel costs account for 60-70% of a power plant’s total operating expenses. Also according to the EIA, the industry benchmark for heat rate is 7,500-8,500 Btu/kWh; however, inefficiencies can increase fuel use by 2-4%, resulting in annual costs of millions of dollars. Here, UptimeAI Expert can work as a unified AI-driven platform to bridge the gaps between reactive maintenance and true operational excellence.

In this case, the thermal power plant producer encountered multiple operational challenges, and the UptimeAI Expert platform was shortlisted to improve asset reliability across 3 phases..

Challenges encountered by the Power Plant:

  • 👉 Anomaly Detection Without Context:
    Anomalies were detected based on DCS alarms without incorporating domain knowledge, relying only on threshold parameters, triggering multiple false alarms and affecting power generation.     
  • 👉 Lack of Asset Failure History for Critical Assets:
    No record of equipment failures or corrective actions taken in the past to guide maintenance decisions, which could save time for future performance.     
  • 👉 Inefficient Collaboration across the Reliability Team:
    Difficulty tracking actual issues and collaborating across departments due to the use of multiple disconnected applications for critical alerts

Discover how UptimeAI helped a 3x 660 MW thermal power producer overcome operational challenges and achieve $10 million in annual operational savings.

 

  

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