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.