Predictive Monitoring Transforms Reliability at Olympia Angel Customer Story Bar Share Customer Information Introduction Industry Power Generation Products SmartSignal Predictive Analytics, Predictive Analytics The Challenge The Olympia Angel power station operates several gas-fired power stations across the UK, with assets including Rock Savage, Spalding, and others dating from 1998 onwards. With upcoming expansions into battery storage and sustainable energy, managing increasingly complex assets emerged as a central challenge that needed to be solved. Additional operational and strategic challenges included: Critical Asset Reliability: Key equipment, such as pumps and valves, represented single points of failure critical to business continuity.Limited Early Warning Capabilities: Prior to implementing predictive monitoring, the company lacked systematic tools to detect and address asset health issues before they escalated.Unplanned Outages: Traditional maintenance practices led to unpredictable failures, costly unplanned outages, and operational risks.Cultural Resistance: Initial efforts at predictive monitoring required significant cultural change, with only small teams or individuals driving adoption. The Olympia Angel plant team purchased predictive maintenance software for early detection to prevent equipment damage such as pictured aboveImage credit: InterGen The Solution – Predictive Monitoring Olympia Angel embarked on a comprehensive predictive monitoring journey over five to six years. The rollout to provide continuous condition monitoring included deploying SmartSignal, with Industrial Managed Services (IMS). The asset monitoring program evolved to enable proactive maintenance planning, foster collaborative team engagement, and enhance detection capabilities through multiple analytical techniques. By integrating regular team reviews, remote monitoring, and continuous learning from past incidents, the organization shifted from reactive to predictive maintenance and established a culture of ongoing improvement. Key Takeaways: Proactive, condition-based maintenance planning replaced reactive responses to failures.Cross-functional teamwork ensured collective vigilance and rapid response to emerging issues.A layered monitoring strategy and diverse analytical tools maximized anomaly detection and supported continuous improvement.Data-driven early warning including asset parameters such as vibration, flow, temperature, and valve position. These were systematically tracked to identify anomalies and trends well before failure. SmartSignal digital twins powered by AI/ML detect developing issueImage credit: InterGen SmartSignal detects hard to detect anomaly in HRSG. Valve pictured to right showing feedback positioner key not in slotImage credit: InterGen The Result Image credit: InterGen The predictive monitoring program delivered significant operational and strategic benefits.Predictive monitoring enabled the team to catch equipment issues early, plan maintenance more efficiently, and steadily improve reliability and performance. The approach reduced unplanned outages, avoided major failures, and shifted the organization’s daily routines toward proactive asset management. Strong management support and a flat structure helped embed these practices, making them adaptable as new technologies and assets were added.Key Takeaways: Reduced Unplanned Outages: Early detection of issues (e.g., pump vibration, valve failures, flow anomalies) allowed timely interventions, reducing downtime and costs while improving performance indicators over time.Optimized Maintenance & Resource Planning: Advance warning enabled the team to schedule outages during low market demand, preorder parts, and minimize business impact.Enhanced Organizational Culture: Predictive monitoring became embedded in daily routines across teams, shifting the focus from reactive firefighting to proactive asset management.Scalability & Adaptability: The layered approach and flexible use of monitoring tools allowed for expansion and adaptation as new assets and technologies were added. Summary:Olympia Angel’s predictive monitoring journey transformed asset management from reactive maintenance to proactive, data-driven reliability. Through early detection, collaborative culture, and continuous improvement, the company achieved greater reliability, lower costs, and a foundation for future growth and sustainability. The program supports Olympia Angel’s transition to more sustainable and renewable energy operations by ensuring reliability and operational excellence across legacy and new assets.The above summary is based upon a presentation given by Ningwei Lu, Performance & Reliability Engineer, in November 2022.