Success Stories

Boosting Power Plant Efficiency

Power Generation
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Boosting Power Plant Efficiency

BKOAI improved power-plant operations through monitoring, proactive maintenance, and staff training to support efficiency and better-informed decisions

Goals

  • Establish a predictive maintenance framework using real-time asset health data for optimal scheduling.
  • Upskill plant personnel to effectively interpret performance dashboards and drive daily decisions.
  • Provide plant leadership with clear historical visibility and predictive analytics to forecast long-term trends.

Challenges

  • Data silos across various equipment and systems restricted the efficient flow of critical operational information.
  • Maintenance schedules lacked the empirical data required to determine optimal servicing times and post-maintenance results.
  • Plant operators lacked the necessary training and experience to leverage visualization dashboards.
  • Limited historical monitoring data prevented leadership from accurately tracking yearly performance trends.

Solutions

  • Developed online monitoring dashboards to enable parameter monitoring and real-time operational visibility.
  • Implemented live health score dashboards assessing the performance of gas turbines, steam turbines, and condensers.
  • Delivered technical training programs to equip onsite personnel with analytical and dashboard interpretation skills.
  • Conducted a comprehensive three-year historical data analysis to identify root causes of equipment inefficiency.

Results

  • Recovered 10 MW of capacity at base load across two critical power generation units.
  • Transitioned plant operations to proactive maintenance scheduling backed by real-time asset performance metrics.
  • Empowered utility leadership to make long-term planning decisions based on verified, up-to-date data.
  • Provided monthly performance and optimization reporting to support grid-reliability planning in Texas.