Innovations in Service for Power Plants: A Game-Changer for the Industry

In today’s world, power plants are faced with a multitude of challenges that necessitate creative, innovative solutions. These technological advancements promise not only to address the industry's challenges but also to enhance reliability in the existing fleet. Service innovations can focus on products, processes or whole new trends in the industry – depending on the specific challenge or need they are designed to address.

Innovative products to enhance sustainability

Consider the vast fleet of power plants in operation around the globe. Transitioning away from fossil fuels might suggest phasing out existing plants and building new installations from scratch. But this approach would pose enormous challenges in terms of time, resources, and costs. Existing power plants appear to be locked into a path leading towards obsolescence. However, there is a way to choose a different path.

In one of my previous articles [https://www.dhirubhai.net/pulse/step-towards-decarbonization-role-hydrogen-gas-turbine-jason-jermark-qrbae/ ], I showed how we can manage the switchover from a gas-fired power plant to incorporate hydrogen co-firing. This is possible through innovative power plant services, as we develop concepts to upgrade the current fleet. Similarly, we have options that can enhance efficiency, lower emissions, and boost the overall performance of existing power plants. This supports our customers in their journey towards a more sustainable future. All this can be achieved by refining our products and tailoring them for integration into existing plants. However, service innovations can go beyond mere product design.

Leveraging data

With our Power Diagnostics? Services, we are monitoring hundreds of engines all over the world every second of the day. The main reason is that we want to detect changes and small irregularities long before they lead to failure. We've been doing this with great success for many years. However, remote monitoring and diagnostics can help us in another way, too. If we look at the vast amount of data we have gathered over time and feed this data into models, we can do Predictive Maintenance: using data analytics to predict when maintenance will be needed. The best part is, these models are dynamic – we can always implement new learnings to improve overall efficiency. This is quite an important capability, considering operating profiles have changed over the past years. For example, some engines and plant concepts that had been designed primarily for base load operation are now becoming peakers. This has a huge impact on material wear and tear, which must be included in the calculation for optimum plant performance. With predictive maintenance, we can optimize the maintenance schedule to find the best fit depending on engine type and operation regime. Consequently, flexible operation capabilities of plants become key when combined cycle units are pushed into intermediate or peaker regime. We developed Flex Power Services [https://www.siemens-energy.com/global/en/home/products-services/service/flex-power-services.html ] to cover all implications, so that plant dispatch and operational costs are optimized. This includes Start Up and Shut Down as well as Low Load Operation, all integrated as holistic power plant solutions based on comprehensive dynamic assessment.

Bringing robots into the game

Of course, we do not stop at optimizing maintenance plans. Service innovations also help us perform maintenance more efficiently than in the past. One example of this is our FAST Gen robotic inspection technology, which offers a range of benefits resulting in a reduction of both downtime and costs.

Traditionally, when conducting a major inspection of a generator, it is necessary to remove the rotor to evaluate the generator's state. In the most extreme scenario, for a single shaft configuration, the generator has to be hoisted off its base to extract the rotor. The solution to this time-consuming method of inspection was the development of a small robot, which allows us to conduct inspections without removing the rotor. This technology not only saves time and reduces costs, but also eliminates the risks of damaging the stator when pulling the rotor. The robot is equipped with a high-resolution camera and can be used for assessments of the stator core interlaminar integrity, generator stator wedges, as well as rotor retaining ring inspections.

And for specific generator series that have a stator slot wedge system requiring periodic re-wedging to restore slot tightness, we can go even beyond mere inspection. Our FAST Wedge system uses a robot to retighten the wedges without removing the rotor. Solutions like these significantly reduce downtime and increase efficiency as well as cost-effectiveness for power plant service.

Integrating new technology fields

There are challenges materializing today that no one could have foreseen a few years ago. Global events have had severe impacts on supply chains. At the same time, we are facing a skilled labor shortage across our industry. These impacts, when combined, lead to numerous additional issues. One such issue is the extended lead times required for component repairs, which can sometimes threaten the safe operation of a power plant and its underlying business model, particularly when it leads to prolonged unplanned outages. Certainly, with predictive maintenance strategies, we can significantly reduce downtime. But what happens when unforeseen disruptions occur, jeopardizing your forecasts? It's vital for profitability that repairs are conducted swiftly to return the asset to service. Traditionally, in the event of a breakdown, the affected part would be detached and returned to the manufacturer for repair, and this process can be logistically complex and time-consuming. Our Additive Manufacturing (AM) system for Onsite Repairs [https://www.siemens-energy.com/global/en/home/products-services/service/am-onsite-repair.html] is a solution that revolutionizes the process. The system, which includes a robot, an additive device or welding head, and a control system, can be deployed and ready for work within hours. The solution is the result of a collaboration of specialists from various disciplines, including Engineering, Non-destructive Testing, Onsite Machining, and Welding. The system can restore components to their original state with minimal distortion and heat effects. It offers a broad range of applications, including Onsite Journal Repair, Onsite Component Repair, and Onsite Rotor Refurbishment, providing efficient and straightforward service to customers worldwide. By producing necessary parts directly at the plant, it eliminates the need for long-distance shipping and cuts down on repair time dramatically. This not only results in significant cost savings but also improves the overall efficiency of the plant.

Service innovations: A path to resilience

However, the path to widespread adoption of such service innovations is not without its hurdles. A key challenge lies in the current shortage of skilled field service personnel. The complex nature of advanced technologies requires a higher level of expertise, emphasizing the need for comprehensive training and education initiatives. Another challenge is the uncertainty and disruption in supply chains. Unpredictable fluctuations in demand and supply can impact the availability of raw materials as well as components. Yet, service innovations like the Additive Manufacturing Onsite Repair can help mitigate these issues by reducing dependency on external suppliers and making the repair process more self-sufficient. As the industry navigates these challenges, it is also witnessing a shift in its requirements and expectations. There is a growing trend towards more sustainable practices, driven by regulatory pressures and changing public sentiments. Here again, service innovations have a crucial role to play. By reducing waste, lowering carbon emissions, and enhancing efficiency, these technologies can help fossil power plants meet their sustainability targets while maintaining their operational viability. In conclusion, service innovations offer a compelling solution to the challenges facing the fossil power plant industry. Not only do they promise significant cost and time savings, but they also contribute to the industry's sustainability efforts. By investing in these technologies and addressing the related challenges, the industry can ensure its resilience in a rapidly changing energy landscape.