Why Power Plants Need to Evolve
Unplanned outages in boilers, turbines, or balance-of-plant (BoP) systems remain a critical threat to power producers. These breakdowns disrupt electricity supply, compromise customer commitments, and result in significant financial losses. Traditional inspection methods—such as manual tube thickness measurements—only cover limited areas and often miss early warning signs. At the same time, the massive amount of operating data generated every second is far beyond human capability to analyze continuously. As a result, subtle but critical risks are easily overlooked.
The Smart Power Plant Approach
REPCO NEX introduces the Smart Power Plant, an integrated solution that leverages predictive technologies, robust digital infrastructure, and advanced operations management platforms. This approach enables power plants to move from reactive responses to proactive strategies.
Key components include:
- Boiler Inspection Robot – Collects 100 times more data than manual methods and reduces inspection time by more than 50%.
- Boiler Digital Twin – A high-fidelity virtual replica that forecasts tube life with accuracy, helping extend equipment lifecycle.
- AI Predictive Analytics – Continuously monitors turbine and boiler performance, detecting anomalies before they escalate.
- Unified Operations Center – A single platform that brings together real-time data, AI insights, and actionable recommendations for faster, smarter decisions.
Proven Results in the Field
The Smart Power Plant is not just a vision—it’s delivering measurable impact:
Boiler outage times cut by more than 50%, enabling plants to recover revenue faster.
Tube life extended through predictive forecasting and optimized operation strategies.
Forced shutdowns prevented thanks to early anomaly detection in turbines and boilers.
Turnaround period extended from 6 years to 9 years or more, reducing maintenance costs and maximizing equipment availability.
Empowering People and Sustainability
Beyond technology, the Smart Power Plant fosters a new way of working. By enabling operators with AI-powered insights, plants can build a culture of digital transformation—where people, processes, and technology evolve together. The result is not only higher reliability and lower costs but also sustainable operations that contribute to energy efficiency and reduced emissions.
