Complete CMMS solution for power plant operations

A Tier 1 nuclear generating station accumulated 14 regulatory citations in a single refueling outage — not from reactor safety failures, but from radiation work permit documentation gaps. Three technicians...

A Tier 1 nuclear generating station accumulated 14 regulatory citations in a single refueling outage — not from reactor safety failures, but from radiation work permit documentation gaps. Three technicians...

Every year, falls from scaffolding and elevated work platforms account for over 300 workplace fatalities and 10,000 serious injuries across construction, maintenance, and industrial sectors. The root cause in...

Every year, hydrocarbon processing facilities report an average of 340 permit-related incidents tied to line breaking and pipe opening activities — ranging from unexpected pressure releases to hazardous vapor...

Managing chemical handling permits across a power plant is a compliance minefield that most operations teams navigate with outdated binders, expired safety data sheets, and permit tracking spreadsheets that no...

Every year, electrical incidents account for nearly 160 workplace fatalities and thousands of severe arc flash injuries across industrial facilities — not because electricians lack skill, but because...

Every year, confined space incidents in power plants account for significant worker fatalities and injuries — not because the hazards are unknown, but because permit management systems fail at the point of...

Every year, industrial plants report an average of 2,400 underground utility strikes during excavation work — each one a preventable incident that costs between $4,000 and $1.2 million depending on what gets...

Every year, power plants report an average of 2,400 fire incidents linked to hot work activities — welding, cutting, brazing, and...

Offshore wind farms now generate over 75 GW of global capacity, but every turbine stands on a submerged foundation exposed to relentless saltwater corrosion, marine growth, and tidal forces. Sending human divers...

Forced outages cost industrial plants an average of $260,000 per hour in lost production, emergency repairs, and cascading equipment damage. Yet most maintenance teams still schedule service based on calendar...

Combined cycle gas turbine plants lose an average of 12–18 equivalent operating days per year to unplanned outages when maintenance is scheduled by calendar alone. Runtime-based maintenance replaces arbitrary...

Auxiliary equipment — chillers, compressors, air handling units, cooling towers, boilers, and backup generators — accounts for nearly 40% of total facility energy consumption, yet most maintenance teams have...

Industrial facilities operating emissions control equipment—scrubbers, electrostatic precipitators, catalytic converters, baghouses, and thermal oxidizers—face a constant balancing act between regulatory...

Electrical transformers are the backbone of every industrial facility, yet most maintenance teams still rely on fixed calendar schedules instead of actual runtime data to plan oil analysis and servicing...

Heat exchangers are the silent workhorses of every industrial facility—transferring thermal energy across process streams around the clock. Yet most maintenance teams still service them on fixed calendar...

Valve actuators in process plants accumulate thousands of operating cycles before anyone checks their condition. By the time a technician discovers a seized actuator or a burned-out motor, the production line is...

Compressors are the workhorses behind every industrial operation—powering pneumatic tools, HVAC systems, refrigeration units, and process lines around the clock. Yet most facilities still track compressor...

Managing a fleet of inspection robots across a power plant without a unified intelligence layer is like dispatching ambulances without a central dispatch — each unit operates blind to what the others are...

Gas turbine blades endure extreme thermal cycling, oxidation, and erosive particle bombardment — yet most repair shops still rely on manual TIG welding and plasma spray processes that introduce operator...

Thousands of miles of high-voltage transmission lines stretch across terrain that punishes human inspection crews — mountain ridges battered by ice storms, river crossings accessible only by boat, and urban...

Power plants increasingly rely on autonomous robots for inspection rounds — thermal patrols through turbine halls, vibration checks on generator bearings, gas detection sweeps across fuel handling areas. But...

Substations and switchyards are the backbone of every power grid, yet their inspection routines remain dangerously outdated. High-voltage bus bars, aging oil-filled transformers, and exposed conductor runs...

By 2026, over 60% of concentrated solar power operators report mirror soiling as their single largest efficiency drain — costing plants up to 40% of annual energy yield when left unchecked. Manual heliostat...

Power plant chimneys and exhaust stacks endure extreme temperatures, corrosive flue gases, and constant thermal cycling that silently erode refractory linings, steel shells, and structural joints. Traditional...

Power plants lose an estimated $50 billion annually to unplanned equipment failures — yet most facilities still rely on calendar-based maintenance schedules that ignore real-time asset health. When AI-driven...

Power plant operators lose an estimated $1.7 million per unplanned outage event on gas and steam lines — yet 61% of pipeline failures originate from defects that robotic crawlers can detect weeks before...

Cooling towers are the thermal backbone of every power plant — and they are deteriorating faster than most inspection programs can keep up. Fill drift eliminates efficiency silently. Basin corrosion weakens...

Power plants operate around the clock in conditions that punish both equipment and the people who inspect it. Turbine halls exceed 90 dB with surface temperatures above 300°C on steam headers. Boiler penthouses...

Utility-scale solar farms lose 15-35% of energy output annually to soiling — dust, bird droppings, pollen, and mineral deposits that accumulate faster than manual crews can clean. A 200 MW plant with 500,000+...

Power plants operate in a relentless cycle of combustion, steam, and generation — turbines spinning at 3,600 RPM, boiler tubes under 2,500 PSI, and cooling systems rejecting megawatts of waste heat around the...

Wind turbine blades stretch 80 meters into the sky, exposed to lightning, rain erosion, and UV degradation year after year. Traditional inspections require rope access teams, weather windows, and turbine...

Nuclear power plants present inspection challenges unlike any other industrial environment — containment buildings with radiation levels that limit human exposure to minutes, spent fuel pools requiring...

Every thermal power plant faces the same hidden risk — thousands of boiler tubes buried deep within furnace walls, economizers, and superheater pendants where manual inspection is dangerous, time-consuming,...

Steel mill hot zones are the most dangerous inspection environments in heavy industry. Blast furnace casthouse floors reach 1,500°C. Coke oven batteries operate at 1,100°C with toxic gas concentrations that...

Power plants are the backbone of global energy infrastructure, but maintaining them has always been a high-risk, high-stakes operation. Turbine halls exceed 90 dB noise levels. Boiler rooms operate at...

Power plants have always been high-stakes inspection environments. Gas turbine enclosures exceed 600°C. Boiler furnace interiors operate above 1,300°C. High-voltage switchyards carry lethal arc flash risks....

Power grid transformers are the backbone of modern electricity infrastructure, yet inspecting and maintaining them remains one of the most hazardous tasks in the utility sector. High-voltage environments,...

Cooling towers are among the most critical — and most difficult to inspect — assets in any power plant. Standing 30 to over 200 metres tall, these massive structures endure constant thermal stress, moisture...

Wind energy now powers over 10% of global electricity, but maintaining turbines spread across remote onshore plains and harsh offshore environments remains one of the biggest operational headaches in the...

Boiler tube failures remain the leading cause of forced outages in fossil-fuel power plants worldwide. The annual economic impact exceeds $5 billion in repair costs, lost generation, and replacement power...

Power plant inspection has always been one of the most hazardous and resource-intensive aspects of plant operations. Turbine halls reach extreme temperatures, boiler internals contain toxic gases, substations...

Nuclear power plants contain some of the most hazardous maintenance environments in any industry. Reactor containment zones expose workers to ionizing radiation measured in millisieverts per hour. Spent fuel...

Solar farm operators worldwide are facing a critical challenge: maintaining peak energy output across thousands of panels spread over hundreds of acres while keeping costs, safety risks, and...

Power plant turbine inspections have entered a transformative era. Traditional approaches — rope-access technicians, multi-week rotor-pull shutdowns, and subjective visual assessments — can no longer keep...

Coal mills are the heartbeat of any thermal power plant — grinding raw coal into fine powder that fuels combustion and generates electricity. A typical 500 MW unit operates 4-6 coal mills, each running...

Cooling tower fans operate in one of the harshest industrial environments imaginable — hot, humid, corrosive air with constant moisture exposure. A typical industrial cooling tower fan runs 4,000-8,760 hours...

Thermal power plants operate boilers under extreme conditions: continuous high-pressure environments at 540-600°C, chemical attack from combustion gases, and thermal cycling stress that degrades critical...

Power plant pumps operate continuously under extreme conditions, yet most facilities still maintain them on fixed calendar schedules that ignore actual wear patterns. A boiler feedwater pump running 8,000 hours...

Generators are the silent guardians of operational continuity — until they fail. When a backup generator doesn't start during a power outage, the consequences cascade immediately: production halts, data...

Steam turbines are the backbone of power generation and industrial processes worldwide, operating continuously under extreme temperatures exceeding 565°C and pressures up to 160 bar. Yet most facilities still...

Power plant pumps operate continuously under extreme conditions, yet most facilities still maintain them on fixed calendar schedules that ignore actual wear patterns. A boiler feedwater pump running 8,000 hours...

Coal mills are the unsung workhorses of every thermal power plant — grinding thousands of tons of raw coal into fine powder that fuels boilers running 24/7. Yet most plants operate their coal mills on...

Cooling tower fans are the unsung workhorses of industrial and commercial HVAC systems, responsible for moving thousands of cubic feet of air every minute to reject heat and maintain process temperatures. Yet...

Boilers are the powerhouse of every thermal power plant — responsible for converting fuel into the steam that drives turbines and generates electricity. Yet most plants operate their boilers with time-based...

Steam turbines are the backbone of power generation and heavy industrial operations, converting thermal energy into mechanical work with remarkable efficiency when properly maintained. Yet across power plants,...

Gas turbines running on fixed calendar-based maintenance schedules waste thousands of dollars every year on unnecessary inspections while...

Organizations still relying on paper-based inspection processes are losing up to 63% more time per inspection compared to digitized...

Power plants running with paper-based BOP inspection systems are losing critical time, missing hidden failures, and...

Power plants running on fuel oil systems face a critical challenge — undetected fuel system failures can trigger emergency shutdowns...

Maintaining a power plant is one of the most demanding jobs in heavy industry. Every turbine, boiler, and generator on your floor represents millions of dollars in capital investment running under extreme...

Power plants running SAP invest millions in their ERP backbone, yet maintenance teams still battle disconnected systems every day. Work orders live in SAP PM while technicians track repairs on spreadsheets....

During a refueling outage at a pressurized water reactor, an inspector discovered wall thinning in a feedwater pipe elbow that had been checked just 18 months earlier. The paper-based inspection log showed...

A turbine technician clears a steam valve blockage. Fifty feet away, a control room operator restarts the system—not knowing anyone is still inside the isolation zone. The result: third-degree burns, a $1.46...

Every power plant generates millions of data points daily—from turbine vibrations to boiler temperatures, generator loads to cooling system pressures. Most of this data sits untouched in historian databases,...

The auditor walks in unannounced. They ask for the maintenance history of your Unit 2 turbine—every inspection, every repair, every calibration for the past three years. Can you produce it in under two...

A turbine blade cracks. A boiler tube leaks. A generator winding fails. Each failure tells a story—one that began weeks, sometimes months, before the actual breakdown. The challenge isn't just fixing what...

A turbine bearing starts running slightly warmer than usual. Vibration patterns shift by fractions of a millimeter. Oil samples show microscopic metal particles that weren't there last month. Individually, these...

Every second, a modern power plant generates thousands of data points—vibration frequencies from spinning turbines, temperature readings from generator windings, pressure levels in steam lines. Plants that...

Bearing failures account for 40-70% of all rotating machinery breakdowns in power plants. When a turbine bearing fails, the consequences cascade quickly—unplanned outages costing hundreds of thousands of...

A single tube failure in a 500 MW boiler requires an average of 3.6 days to repair and costs more than $3 million in lost generation and maintenance expenses. Yet the leak itself often starts as something...

That slight temperature drop across your feedwater heater wasn't there last month. Your operators logged it, but nobody escalated it. Now, six weeks later, you are looking at a tube leak that's contaminating...

Your power plant runs 168 hours every week. Each hour, your boilers, pressure vessels, and turbines accumulate stress, corrosion, and fatigue damage that no calendar-based inspection schedule can accurately...

Your maintenance technician just completed a critical turbine repair. Now comes the frustrating part: logging into SAP, navigating complex transaction codes, manually entering work order details, and hoping the...

Every maintenance manager knows the frustration: you've got hundreds of assets to monitor, but the same few troublemakers keep causing 80% of your headaches. According to the National Energy Technology...

Your turbine gets serviced every 6 months like clockwork—whether it needs maintenance or not. Meanwhile, a bearing that actually needs attention gets overlooked because it's "not due yet." Sound familiar? This...

When a turbine bearing fails at 2 AM, your plant doesn't just lose power generation—it hemorrhages money at $125,000 per hour. Add emergency contractor premiums, expedited parts shipping, and grid penalty...

Your baseload plant wasn't designed to cycle. But now it's starting up cold three times a week, chasing renewable intermittency and market signals. Every startup sends thermal shock waves through boiler tubes,...

The turbine tripped again last Tuesday. Same unit, same symptoms, same $125,000-per-hour losses. Your maintenance team fixed it—again—and everyone moved on. But here's the uncomfortable truth: without...

A single turbine bearing failure at 2 AM costs more than the repair bill. It costs $125,000 per hour in lost generation, emergency contractor premiums, and the cascading effects on grid commitments. Now imagine...

Your control room has data everywhere—SCADA screens showing real-time valve positions, DCS displays monitoring turbine temperatures, historians storing years of operational records. But when your plant manager...

The load ramp started at 14:23. By 14:31, Unit 3 was offline. Eight minutes—that's how quickly an operator decision error during a routine load change can cascade into an unplanned shutdown. The operator...

At 2:47 AM on a Tuesday, a bearing in your 400MW steam turbine begins its final failure sequence. By 3:12 AM, the unit trips offline. By sunrise, your operations team is scrambling to source replacement parts...

Your 500MW turbine generator has been operating at 3,600 RPM for eleven months straight. The vibration readings look normal on the control room screens. Temperature sensors show values within acceptable ranges....

It's peak summer demand. Your 500-MW unit is running at full load when suddenly, ash slurry flow drops to zero. A blockage has formed in your pipeline—silently, without warning. Within...

It's 3:17 AM. Deep inside your 500-MW boiler, a hairline crack begins venting high-pressure steam—too small to trigger alarms or be noticed by operators. For hours, the leak grows...

At 2:47 AM on a Tuesday, a bearing in your gas turbine fails. By the time your operations team diagnoses the problem and coordinates emergency repairs, eighteen hours have passed. The direct repair costs:...

Your gas turbine has been running hot for the past six days. Not alarmingly hot—just 12°C above baseline exhaust temperature. Your operations team noticed it, logged it, and scheduled an inspection for next...

A single turbine bearing failure can cost your power plant $150,000 or more in emergency repairs—plus days of lost generation revenue. Bearing failures account for 40% to 90% of rotating machinery failures...

Your condenser's cleanliness factor has been declining—83% last month, 81% two weeks ago, 79% yesterday. Each reading passed the 75% alarm threshold. But nobody noticed the trajectory. By the time operations...

Your feedwater heater's Terminal Temperature Difference has been creeping up for three months—from 5°F to 8°F to 12°F. Each reading looked acceptable in isolation. But nobody connected the dots. By the time...

It's 2:47 AM. The night shift operator notices a slight temperature rise on pump bearing #4—just 3°C above normal. He logs it in his paper notebook and mentions it during the 6 AM handover. But the day shift...

A hairline crack on a turbine blade—invisible to the naked eye—grows silently for 6,000 operating hours. Then, without warning, it propagates through the blade root, liberating a 2-pound fragment at 15,000...

A metal bolt falls from an overhead walkway onto your coal conveyor belt. Within seconds, it reaches the crusher—and in an instant, you're facing $180,000 in emergency repairs, 36 hours of unplanned downtime,...

Your boiler is operating at 2,340 PSI. The gauge shows green. Steam generation stays within normal range. But beneath that stability, pressure values are trending upward—not violating limits yet, just...