Improving boiler reliability and reducing tube failures at global chemicals and energy company
At one of its major industrial facilities, a global chemicals and energy company, relies on a complex steam system to support petrochemical production, refining processes, and on-site electricity generation. At the centre of this is a fleet of 12 coal-fired boilers, some dating back to the 1950s and 1980s, each capable of generating up to 163 tonnes of steam per hour. The steam they produce is essential not only for internal operations but also for external industrial clients and embedded power generation.
By 2016, the reliability of this boiler fleet had become a growing concern. Boiler tube failures were increasing, disrupting steam production and affecting both internal processes and external supply commitments. Addressing this required more than reactive maintenance. It called for a more structured, data-driven approach to understanding asset conditions and managing risk across the fleet.
Asset Performance Partners (APP), working alongside the company through its APP Performance Platform and associated managed services, began supporting the local team in early 2017, specifically focussing on reducing boiler tube failures on their fleet of boilers
THE CHALLENGE
Ageing assets, fragmented information and increasing boiler tube failures.
The industrial facility’s boilers were ageing assets operating in a demanding production environment. At the same time, decades of valuable design, inspection, condition and operational data existed across the fleet, but much of it was fragmented or difficult to access. Critical failure information required for optimising decision-making was often not adequately investigated or captured. This made it harder to build a clear, consistent view of asset health.
Maintenance decisions were being made under pressure, often without the benefit of integrated data or clear risk insight. Boiler tube failures, a common but critical issue in coal-fired boilers, were occurring with increasing frequency. These failures directly affected steam availability and, by extension, production stability and energy generation.
The risk extended beyond individual incidents. Without a systematic way to interpret historical and real-time data, there was a danger that underlying degradation mechanisms would remain undetected until failure occurred.
THE APP APPROACH
Turning fragmented asset information into structured, risk-based action.
APP’s approach combined platform capability with hands-on asset management support, guided by relevant specialist input on best practices. The starting point was the digitisation and integration of legacy asset data. Historical design records, inspection results, condition data and operational performance information were collected, converted and structured within the APP platform.
Once consolidated, this data could be analysed using risk algorithms and analytics designed to identify emerging failure patterns. The platform enabled teams to visualise trends, understand degradation mechanisms and make more informed decisions about maintenance and inspections.
The approach also included structured programmes aligned with recognised industry practices, such as boiler tube leak reduction methodologies, supported by data-driven analysis and prioritisation.
Beyond analytics, the platform supported maintenance and inspection work. Virtual project tracking enabled teams to manage tasks in real time, including quality-control checks and technical acceptance of completed work. This ensured that decisions translated into consistent and verifiable actions on site.
RESULTS AND VALUE DELIVERED
Sustained reliability improvements delivered measurable operational and financial value.
The impact of this approach became visible over several years of sustained implementation. Across the boiler fleet, forced boiler shutdowns due to boiler tube failures were reduced from approximately 26 incidents per year to seven, representing a reduction of around 66%. This brought the fleet below the global benchmark, a significant improvement for an ageing fleet of 12 coal-fired boilers. This improvement was supported by the sustained implementation of data-driven maintenance and inspection decisions supported by the platform and associated services.
These improvements in reliability translated into broader operational benefits. As boiler integrity-related failures decreased, more steam became available across the system. Over the period from March 2018 to June 2019, this additional steam supply enabled increased electricity generation through the facility’s turbo-generators, reducing reliance on external electricity supply. The resulting savings were estimated at approximately $3.5 million over that period.
From a commercial perspective, the reduction in failures and improved operational stability contributed to an estimated $10 million in profitability impact.
A MORE STRUCTURED APPROACH
Creating a stronger foundation for ongoing asset performance.
Beyond the immediate improvements in reliability, the engagement introduced a more systematic way of managing boiler performance. The local team gained a clearer, more integrated view of asset conditions, supported by both historical and real-time data.
Maintenance and inspection decisions became more consistent and better aligned to actual risk. Teams were able to identify and address emerging issues earlier, reducing the likelihood of unexpected failures and improving overall plant stability.
Importantly, the approach also supported continuity. By digitising and structuring asset knowledge within the platform, critical information was no longer dependent on individual experience or isolated records. This created a more durable foundation for ongoing asset management.
LOOKING AHEAD
Supporting sustainable performance across an ageing boiler fleet.
For the global chemicals and energy company, improving boiler reliability was not a once-off intervention but a shift in how asset performance is managed. With a more structured view of asset health and a clearer basis for decision-making, the operation is better positioned to sustain performance across an ageing fleet while supporting future operational and energy requirements.
For APP, the engagement reflects the role that integrated data, engineering insight and structured execution can play in improving performance at scale. In complex industrial environments, the difference between reactive maintenance and informed decision-making is often measured not only in reliability, but in sustained operational and financial value.
