$500K+ in damage and downtime avoided by catching inlet filter obstruction
Author Sticky
Jacqueline Vinyard
GE Vernova’s Software Business
May 27, 2025
3 Minute Read
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Anomaly Detected: Drop in fan discharge pressure, indicating reduction in critical cooling air supply.
Diagnose: Inlet filter of the fan was obstructed. Pressure transmitter wasn’t measuring or alarming correctly.
Prioritize: Immediate action was taken to replace filters.
Impact: Estimated savings of $543,120 in costs associated with potential turbine damage and production downtime.
Diagnose: Inlet filter of the fan was obstructed. Pressure transmitter wasn’t measuring or alarming correctly.
Prioritize: Immediate action was taken to replace filters.
Impact: Estimated savings of $543,120 in costs associated with potential turbine damage and production downtime.
Predict: What did GE Vernova’s SmartSignal predictive analytics software?
At the metals and mining site of a major industrial company in Europe, a major equipment downtime risk was identified and mitigated with the help of SmartSignal, GE Vernova’s AI/ML predictive analytics software. Unexpected downtime on the customer’s 9HA.02 gas turbine was prevented by combining GE Vernova’s APM SmartSignal software with advanced monitoring services, together called M&D with SmartSignal. M&D with SmartSignal includes an assigned GE Vernova engineer to monitor the centerline equipment and may also include coverage of other critical balance of plant (BOP) equipment (ie: condensers, transformers, and cooling water systems).
The anomaly was detected by the software's digital twin, which revealed a progressive drop in the running exhaust frame fan discharge pressure. A reduction in the critical cooling air supply pressure from the fan can indicate underlying mechanical problems on the cooling and sealing air circuit that may require further investigation and intervention.
The M&D with SmartSignal assigned engineer assessed the urgency of the issue and reported the anomaly, along with recommendations on next steps to address the findings. The issue was subsequently followed up the regular weekly discussions with the customer.
The anomaly was detected by the software's digital twin, which revealed a progressive drop in the running exhaust frame fan discharge pressure. A reduction in the critical cooling air supply pressure from the fan can indicate underlying mechanical problems on the cooling and sealing air circuit that may require further investigation and intervention.
The M&D with SmartSignal assigned engineer assessed the urgency of the issue and reported the anomaly, along with recommendations on next steps to address the findings. The issue was subsequently followed up the regular weekly discussions with the customer.
Diagnose & Prioritize: What was the underlying cause and risk urgency?
Following the guidance of the GE Vernova M&D with SmartSignal engineer, the customer plant team conducted an investigation in the field. The investigation revealed that the inlet filter of the fan was obstructed. However, this issue was missed because the filter differential pressure transmitter was not measuring correctly and failed to alarm on the impaired condition of the filter. The M&D with SmartSignal discovery prompted immediate action, and the customer replaced the dirty filters.
To verify that the replacement resolved the pressure decline, the assigned M&D with SmartSignal engineer monitored the equipment. The replacement proved to be the correct solution, as the discharge pressure returned to the model-predicted value, effectively restoring the system's performance to its expected operational parameters. The customer subsequently attended to the inlet filter differential pressure transmitter to restore its function, so it correctly measures and alarms in case of excessive filter fouling.
To verify that the replacement resolved the pressure decline, the assigned M&D with SmartSignal engineer monitored the equipment. The replacement proved to be the correct solution, as the discharge pressure returned to the model-predicted value, effectively restoring the system's performance to its expected operational parameters. The customer subsequently attended to the inlet filter differential pressure transmitter to restore its function, so it correctly measures and alarms in case of excessive filter fouling.
Customer Impact
The turbine exhaust is subjected to high temperatures and must be cooled as soon as the rated speed of the turbine is reached, especially at high loads. This is necessary to prevent structural deformations of its structure as well as damage to critical instrumentation installed within the load tunnel.
The timely identification of the anomaly through M&D with SmartSignal, along with recommendations from GE Vernova’s Engineering team, helped the customer understand the risk and take prompt action to investigate. The issue was corrected without incurring any loss of production or damage.
As shown by GE Vernova's verification, the actual values returned to their expected levels. The intervention helped prevent potential turbine damage and production downtime. This is estimated to have avoided approximately $543,120 in associated costs.
*Avoided costs are based on North American average production loss.
The timely identification of the anomaly through M&D with SmartSignal, along with recommendations from GE Vernova’s Engineering team, helped the customer understand the risk and take prompt action to investigate. The issue was corrected without incurring any loss of production or damage.
As shown by GE Vernova's verification, the actual values returned to their expected levels. The intervention helped prevent potential turbine damage and production downtime. This is estimated to have avoided approximately $543,120 in associated costs.
*Avoided costs are based on North American average production loss.
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