Condition Monitoring for Power Generation

The sub-sectors with the highest equipment criticality and longest production runs. Within Reliability Consulting for Power Generation Plants, that's typically operations running large rotating equipment 24/7 on tight production schedules. Smaller Reliability Consulting for Power Generation Plants operations with mostly batch work and shorter equipment populations get less leverage from Condition Monitoring and may be better served by basic preventive maintenance with on-call diagnostic support.

The lead findings on a typical first-year Condition Monitoring program at a Reliability Consulting for Power Generation Plants site cluster around progressive mechanical and lubricant degradation. In Reliability Consulting for Power Generation Plants specifically, those failure modes show up faster because of large rotating equipment, NERC bulk power compliance. Lead time before functional failure runs 200-2000 hours — long enough to schedule the repair into a planned outage rather than firefighting at 2 a.m.

Site walk to scope the asset population, criticality scoring against turbine reliability, generator winding condition, boiler tube integrity, baseline measurements on the top 30 to 60 assets, then a regular cycle of monthly on critical assets, quarterly on B-criticality. Findings get written up against ISO 17359 and ISO 13374. For Power Generation facilities, the engagement usually includes coordination with the plant's existing compliance program — pulling Condition Monitoring results into the NERC PRC-005, EPA MATS, OSHA arc flash audit file. Initial scope runs $15K-$45K depending on asset count, then ongoing at $180-$300 per asset per month.

Sub-sectors with the highest equipment criticality and longest production runs. Within Power Generation, that's typically operations running large rotating equipment 24/7 on tight production schedules. Smaller Power Generation operations with mostly batch work and shorter equipment populations get less leverage from Condition Monitoring and may be better served by basic preventive maintenance with on-call diagnostic support.