Steam Turbine MRO Operations: Impact of AI and Machine Learning on the Industry

Highlights:

• Introduction
• Innovations in the steam turbine MRO industry
• Acquisitions and partnerships in the sector

Steam turbines are heat engines that draw thermal power from pressurized steam and convert it to mechanical energy for driving different machines like electric generators. Steam turbines are some of the most widely used components in the power generation sector. They are deployed in fossil fuel power plants, nuclear energy stations, desalination facilities, cogeneration processes, and other industrial applications. Along with this, the growing demand for renewables has expanded the utility of steam turbines in recent times. As per the International Renewable Energy Agency (IRENA), the share of renewable energy generation is expected to grow from 16% in 2020 to more than 75% by 2050. With the increasing use of steam turbines, the demand for maintenance, repair, and overhaul (MRO) operations is expected to rise significantly.

Latest advancements in MRO techniques driving industry growth

Steam turbines are highly susceptible to corrosion and erosion, which results in a reduction in heat transfer and an increase in the overall pressure drop. This enhances the risk of component failure and outages, resulting in the breakdown of the machinery. Furthermore, fouling and deposit buildup on the blades and rotors bring down the aerodynamic efficiency and power output substantially. In extreme cases, thermal fatigue and creep damage can lead to the catastrophic failure of the entire turbine. To avoid these scenarios and improve the overall efficiency and productivity of the machine, regular steam turbine MRO operations are essential.

One of the latest MRO techniques that have evolved in recent times is vibration analysis, which studies the frequencies and vibration levels found in the turbine to determine its health and reliability. This methodology enables companies to detect faults in mechanical components and diagnose the severity of the problem. Moreover, in the last few years, the emergence of various digital technologies, such as AI, machine learning, and data analytics, has improved the quality of MRO operations significantly. AI tools and ML algorithms process large volumes of data and identify the possible issues that are likely to arise in the future. The predictive maintenance capabilities offered by these solutions make them indispensable to modern maintenance and repair procedures. Furthermore, the use of IoT-based sensors, imaging technologies, and data analytics software programs aid in automating most of the inspection processes and enhance the accuracy and precision involved in performance modeling.

Partnerships and acquisitions by major companies creating investment opportunities

The growth of the steam turbine MRO industry is attributed to the strategic alliances established by leading companies in the market. The sector, which accounted for $22.6 billion in 2023, is predicted to gather a revenue share of $37.4 billion by 2033, rising at a CAGR of 5.2% during 2024-2033. In September 2021, PT Garuda Maintenance Facility Aero Asia Tbk (GMF AeroAsia), an aircraft maintenance company in Indonesia, announced a partnership with PT Sulzer, a rotating equipment manufacturer. A memorandum of understanding was signed by these two firms to collaborate in aero-derivative turbine maintenance, component repair services, and other engineering solutions. Furthermore, both companies agreed to share their resources and expertise on marketing operations, logistics, and networking expansion.

In August 2022, AP4 Group, an aftermarket provider of turbomachinery maintenance services, announced the acquisition of Hughes Technical Services, an engineering solutions company. Hughes Technical Services was the leading MRO services provider for Alstom™ power generation equipment and industrial gas turbines, and this business move enabled AP4 Group to take over HTS’s clients, thus expanding its footprint in the industry. Greg Young, President and CEO of AP4 Group, highlighted that the acquisition broadened the customer base of the company and is expected to assist the firm in catering to the diverse demands of the market comprehensively. Over the years, AP4 Group has emerged as one of the major players in engineering automation, component repair, and MRO services.

Winding up, the increasing applicability of steam turbines in power generation and industrial processes is expected to create favorable conditions for the growth of the industry. Additionally, the transition toward renewables and the advent of innovative techniques have opened new avenues for investments in the market. Moreover, the integration of AI and data analytics in MRO operations is expected to bring in numerous opportunities in the sector.

Reach out to our experts for insights on the latest growth drivers and opportunities in the industry!

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