Power Generator Lifts Fleet Availability 6 Points with Unified Asset Performance Analytics
A multi-fuel power generator consolidated historian, SCADA, and work-order data into a Databricks lakehouse on AWS — turning reactive maintenance into condition-based asset strategy across 9 GW of capacity.
A power generator operating a 9 GW multi-fuel fleet — gas, wind, and solar — had its operational data trapped in per-plant historians, OEM portals, and a 20-year-old work-order system. Fleet engineers could not compare asset health across sites, availability was eroding as the fleet aged, and forced outages during peak-price windows were costing millions per event in lost merchant revenue and replacement power.
Apptad built a fleet-wide asset performance platform: historian and SCADA streams landed in a Databricks lakehouse on AWS, harmonized against an asset registry we rebuilt with consistent taxonomy across all sites. On top, we delivered condition-based health scoring per asset class — gas turbines, wind gearboxes, inverters — degradation trending, and outage-risk dashboards that rank the fleet by revenue at risk, integrated into the existing work-order system so insight lands as scheduled work.
Fleet availability improved 6 percentage points in the first full year, with forced-outage rate down 28% on the covered asset classes. Engineers now run one fleet-wide view instead of nine plant silos, maintenance spend shifted 35% from reactive to planned, and the platform flagged two developing turbine failures early enough to schedule repairs into planned outages — avoiding an estimated $11M in peak-window losses.
The Numbers Behind the Story
Built On
The platforms and partners that powered this engagement. Where Apptad has a dedicated alliance, the chip links to our partnership page.
“We ran nine plants on nine versions of the truth. Now the whole fleet is one screen, ranked by risk and revenue — and we fix things before they fail, on our schedule.”
