Utilities

How predictive maintenance and machine health monitoring protect critical assets

Boiler Feed Water Pumps + -

Most industrial pumps operate at less than half of their potential efficiency, usually due to poor operating conditions and practices that can be impossible to pinpoint with traditional approaches to maintenance.

Pumps consume 25% of all industrial energy
Pumps typically operate at 40% efficiency
Inefficiency costs $500,000 on average over the pump’s lifespan

Motors and pumps with large pipes in a utilities plant.

Cooling Towers + -

Cooling towers are hard to reach and hard to monitor, so many maintenance pros miss key indicators of imminent failure. Tower failure can have downstream impacts on almost all production processes.

$1,000/hour downtime cost
$50,000 in equipment costs per failure
$100,000+ cost savings per avoided failure

Induced/Forced Draft Fans + -

Route-based maintenance doesn’t capture the full picture of ID/FD fan health. These fans are large, putting relatively small data anomalies lower on the priority list — but they are often a warning sign of imminent failure.

Up to $20,000/hour downtime cost
$250,000 in equipment costs per failure
$300,000+ cost savings per avoided failure

"By deploying sensors and optimizing the strategy, they reduced this cost to about $1.8 million, saving roughly $900,000 over three years."

Thom Brotski, CEO
Harrison Group LLC

Customer Success Story

"There was stuff that we weren't even necessarily considering monitoring, and that was the first thing we found faults on."

Jon Driscoll, Information Technology Coordinator
Altoona Water

Customer Success Story

"I can’t thank KCF enough. The relationship has been great. Despite being a small operator, we get treated with the same care and attention as bigger companies."

Jon Pharr, Regional Operations Manager
EDL Energy

Customer Success Story

"We're getting a lot more catches because the guys aren't having to diagnose it. It's telling them. We're much more responsive and we're getting four times as many catches as we used to."

Mark Rosen, President U.S. Division
Calfrac Well Services

Customer Success Story

Q&A session featured at the 2024 Manufacturing the Future Summit.

Executive Panelists

Q&A session featured at the 2024 Manufacturing the Future Summit.

Lou Romano, KCF Technologies
David Bonfante, Georgia-Pacific
Tatiana Borges, RigCLOUD
John Eutsey, Synthomer
Alex Puentes, Carpenter Technology

View All Keynotes

Case Study Spotlight

Leveraging predictive maintenance to minimize thermal losses

Talen Energy: $2.5M - $10M in savings.

Nuclear power plants use large amounts of water for cooling, with more than half of the energy produced by a nuclear power plant lost as heat. However, accurately tracking thermal output can be a challenge.

Susquehanna Steam Electric Station (SSES), a division of Talen Energy, was tasked with addressing this industry-wide problem and partnered with KCF Technologies to develop a solution. Through a comprehensive hardware and software platform, SSES is already seeing quick wins from its new investment.

Read Case Study

Improve thermal performance

Replace time-based maintenance with as-needed maintenance.
Detect thermal losses in real time with continuous pressure and temperature monitoring—so you can prevent lost megawatts and avoid costly heat rate inefficiencies.

Prioritize, plan, prevent

Prioritize maintenance activities based on criticality instead of best guesses.
Use real-time asset data and AI-driven insights to prioritize maintenance by criticality, avoid unnecessary shutdowns, and prevent costly unplanned downtime.

Related case studies

Vacuum Pump

Vacuum Pumps

Vacuum pumps are critical in many manufacturing processes. KCF's comprehensive machine health monitoring empowers you with the data and insights needed to minimizing unplanned downtime.

View Case Study

Talen Energy Case Study

See how KCF helped Talen Energy leverage advanced wireless machine health monitoring to optimize performance and minimize thermal losses.

View Case Study

Fan Pump

Municipal utility district technical insights

See how machine health monitoring with SMARTdiagnostics can eliminate unplanned downtime due to blower and pump failures for municipal utilities and wastewater management.

View Case Study

$ 4 Billion+

in customer savings

85,000

hours of downtime prevented

1.2 Billion

data points per month

Request a demo

Want to eliminate unplanned downtime and extend the lifespan of your critical assets?
Contact us to see how our comprehensive, AI-driven machine health platform can optimize your operations.

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Trusted by industry leaders in critical infrastructure

How predictive maintenance and machine health monitoring protect critical assets

Gain a competitive edge with KCF

Executive Panelists

Leveraging predictive maintenance to minimize thermal losses

How our machine health optimization platform works

Improve thermal performance

Prioritize, plan, prevent

Related case studies

Why KCF

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