Gas turbine prescriptive maintenance: from alerts to actionable interventions
Global integrated energy operator
$650K to $1.9M estimated annual value per high-criticality turbine, payback typically within 6 to 12 months
Challenge
A fleet of high-value industrial gas turbines had condition monitoring capable of detecting abnormal sensor behavior but unable to distinguish causes from symptoms or guide intervention decisions. Teams received alerts without actionable guidance, resulting in unnecessary outages and degradation that progressed further than necessary.
Approach
A causal turbine degradation model was built from vibration, acoustic, thermal, pressure, flow and operational data combined with maintenance and outage history. Rather than generating a risk score, the system compared specific intervention options and estimated the financial impact of each course of action.
Outcome
The operator shifted from reactive alert management to prescriptive intervention planning. More maintenance aligned to planned windows, unnecessary outages were avoided, and every maintenance decision was supported by a quantified financial justification and a clear causal rationale.