€910,000 Saved at a Solar Thermal Power Plant

Location: Spain
Application: Solar Thermal Energy

EXECUTIVE SUMMARY

DSP Analytic, a spanish company specializing in technical Operation and Maintenance (O&M) solutions, successfully used ACOEM’s FALCON portable solution and its proprietary health matrix to proactively diagnose a critical failure on a steam turbine in a 50 MW solar thermal power plant. This early detection prevented a major production shutdown, saving the end-customer an estimated potential loss of €910,000. This success has solidified our client’s position as a leader in predictive maintenance within the renewable energy sector in Spain.

The Challenge

The main challenge was turbine trips due to random high vibration levels, leading to unplanned production stoppages.The potential consequences were a production loss of 50 MW, contractual financial penalties, degradation of the asset’s condition and a reduction in its lifecycle, as well as collateral damage to other equipment.

This challenge led to increased O&M costs, the need to schedule expensive inspections, and warranty disputes with the equipment manufacturer.

The Solution

The client implemented a Condition-Based Maintenance (CBM) program using the FALCON portable vibration analyzer from ACOEM.

The client chose the ACOEM solution because it offered the highest possible quality of service, based on a deep knowledge of the machine to be monitored. The combination of the FALCON and the health matrix allowed for effective parameterization to automatically detect condition changes and diagnose the failure mode.

The solution made it possible to diagnose the root cause of the vibrations. Thanks to regular measurements (every 3 months) with the FALCON, the client was able to track the evolution of the machine’s condition and detect the failure long before the asset’s own online monitoring and protection system, enabling proactive action.

The Results

The client successfully detected a complex failure mode including gear misalignment and eccentricity, gear overload, and sleeve bearing fatigue. This early diagnosis allowed for the planning of a maintenance intervention and the avoidance of a catastrophic failure.

If the failure had not been detected, the total estimated cost (10-15 days of unavailability + component replacement) would have been €910,000.

The Impact

€910,000 avoided losses (downtime + parts)
Increased asset lifespan through timely intervention
Improved operational reliability and reduced risk of cascading failures
Enhanced predictive maintenance capability, combining existing protection systems with periodic CBM measurements for maximum coverage
Greater competitiveness in delivering consistent, clean energy output

This case proves that periodic condition monitoring is a powerful complement to permanent protection systems — ensuring earlier fault detection, better maintenance planning, and significant cost avoidance.

Beyond the direct savings, this achievement demonstrates how a periodic condition-based maintenance program, supported by the FALCON portable solution, provides end users with higher reliability of their critical turbomachinery. By complementing existing protection systems, it reduces unexpected failures, extends equipment lifetime, and ensures safer, more efficient operations.