Powering Efficiency: How PredCo's Predictive Maintenance Transforms Coal Plants

Predictive Maintenance
April 4, 2024
2 minute read
Powering Efficiency: How PredCo's Predictive Maintenance Transforms Coal Plants

Coal-based energy generation plays a significant role in meeting global energy demands. In India, it accounts for a massive 55% of the country's energy needs; however, it faces several challenges that impact operational efficiency and reliability. Coal-fired power plants rely on complex systems such as boilers, turbines, and generators, each comprising various critical components and parameters that need appropriate surveillance. Proper upkeep is required for these devices, which otherwise leads to the degradation of overall plant efficiency and unwanted costs associated with downtime, affecting energy production and profitability.

The most frequent challenges the coal-energy industry faces are associated with malfunctioning of the critical devices used in its operations.

  • Fluctuations in flue gas temperature, feedwater flow, steam pressure, and vibration levels of the boilers can reduce efficiency and potential equipment damage.
  • Variations in turbine vibration, speed/load, lubricating oil condition, and temperature can affect turbine performance and reliability.
  • Issues like stator winding temperature, rotor speed/vibration, output voltage/current, and cooling system performance can impact generator efficiency and longevity.

PredCo’s Advanced Predictive Analytics Solutions

PredCo offers predictive maintenance solutions tailored for coal-based energy generation plants, leveraging advanced AI and machine learning technologies.

  • Continuous Monitoring: Our system monitors critical parameters of boilers, turbines, and generators in real time, including temperature, pressure, vibration, and flow rates.
  • Machine learning Algorithms: PredCo analyses historical and real-time data using sophisticated machine learning algorithms to identify patterns, trends, and anomalies, proactively informing potential equipment failures or performance degradation.
  • Alerts and Proactive Maintenance: PredCo offers Watchers as an essential feature for continuously checking the parameters and devices. Our system allows users to preset thresholds and alerts operators to take proactive measures, such as scheduling maintenance activities or adjusting operational parameters, in case of deviations.
  • Twin Monitoring: The Digital Twin feature enables a holistic asset performance visualization of the turbines, boilers, generators and other critical equipment, enabling early detection of bottlenecks and empowering users with data-based decision-making.

Through continuous monitoring of critical parameters and leveraging advanced machine learning algorithms, PredCo's predictive maintenance solutions offer transformative benefits to coal-based energy generation facilities:

  • PredCo's solutions minimize unwanted downtime by up to 35-45% through proactive maintenance, ensuring uninterrupted turbine operation.
  • This proactive approach helps reduce energy production losses by up to 15% by preventing equipment failures and optimizing plant efficiency.
  • By extending equipment lifespan by up to 20%, PredCo enables coal-based energy facilities to enhance operational efficiency and maximize the longevity of critical components.

PredCo is at the forefront of empowering the coal energy generation industry to optimize performance, minimize downtime, and contribute to a sustainable energy landscape. With PredCo's innovative solutions, coal-based energy facilities can transition towards more efficient and environmentally friendly operations, ensuring a brighter future for generations to come.