Condition monitoring is helping old power stations stay on the grid
The global energy transition may be underway, but much of the world's electricity still flows through ageing infrastructure. In Europe, more than a third of thermal power plants are over 30 years old. In emerging economies, older coal and gas-fired stations remain vital to meeting growing demand. Faced with uncertain timelines for replacement and rising pressures on reliability, operators are turning to a once-overlooked discipline: condition monitoring.
Rather than replacing ageing assets wholesale - a prohibitively expensive endeavour for most utilities - firms are investing in ways to understand the machinery they already have. Condition monitoring uses sensors to track key indicators such as vibration, temperature and shaft displacement. The data are then analysed to detect early signs of wear or failure, ideally before either becomes critical.
The principle is simple: fix machines only when they show signs of needing it. That approach, known as predictive maintenance, is a marked departure from conventional schedules based on calendar time or operating hours. It is also more efficient. By targeting interventions, operators reduce downtime, prolong the life of critical components, and avoid cascading failures. That, in turn, means older stations can be run safely for longer.
Turbines are a particular focus. Unchecked rotor vibration or bearing failure can spell disaster. Modern systems such as the Sentry G3, a digital protection unit made in the UK, offer real-time monitoring of multiple dynamic parameters. These can be integrated into control-room dashboards, alerting engineers to anomalies before they become emergencies.
The cost is modest compared with the alternatives. An unexpected turbine failure can cost millions and force plants offline for weeks. Sensor arrays and diagnostic software, by contrast, are relatively cheap to install and scale. Moreover, the data they generate can feed into longer-term asset strategies, helping firms decide which parts of their fleet are worth keeping and which should be retired. Condition monitoring will not eliminate the need to replace old power stations. But it can buy time – and in a grid strained by renewables intermittency, geopolitical disruptions and rising demand, time is a valuable commodity. To explore how this could work for your operations, get in touch with us today.
