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Efficiency Signal gives utilities physics-based analytics on the data their plants already collect, with computer vision that reads condenser datasheets, to inform maintenance of steam condensers.

Digital Twin & Predictive Maintenance for Condensers

CondenserSentinel™ turns the data your plant already collects into early warnings, likely-cause diagnosis, and executed fixes. Low CapEx. Low OpEx.
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  • AVEVA
  • Bionetics
  • AES
  • DiPhyx
  • AWS
EPRI'S OPEN POWER AI CONSORTIUM NAMED USING DATA ANALYTICS TO INFORM CONDENSER MAINTENANCE A TOP-4 AI USE CASE

Steam condensers sit behind 80–85% of US power production, and almost nobody can see inside them.

1–3% OUTPUT LOST · $250K–$340K/DAY AT RISK, INDUSTRY ESTIMATES
The problem isn't a lack of data. It's that nothing acts on it, until now.
DCSSCADAHISTORIANOEM SPECSFIELD SENSORSONE SIGNAL

CondenserSentinel™ drives Maintenance Planning and Execution.

CondenserSentinel™ — ALERTILLUSTRATIVE MOCK-UP
AIR IN-LEAKAGETUBE FOULINGCW FLOW
DRIFT DETECTED, 22 DAYS BEFORE THRESHOLD

Same data. Same physics. Weeks earlier.

40120240SCFM~3 MONTHSMW500150CONDENSERSENTINELWOULD HAVE FLAGGED HEREMODELLED SCENARIOAIR IN-LEAK BEGINS · 40 SCFMOUTPUT FORCED TO 150 MW~8,400 MWh/DAY LOSTDIAGNOSED: CROSSOVEREXPANSION-JOINT CRACKREPAIRED → 10 SCFM150 MWRESTORED
ILLUSTRATIVE RECONSTRUCTION OF A RECORDED CASE: TIMELINE AND INSTRUMENT VALUES ARE REPRESENTATIVE.
The manual forensics behind this recovery took weeks of expert time. CondenserSentinel™ predicts and flags the drift weeks earlier.
“E-Signal allows our dispatches to be far more efficient, identify root causes faster, and lower maintenance costs for our clients.”
BOB MECHEM · AMERICAN EFFICIENCY SERVICES

A 1% increase in MW production from more timely diagnosis and intervention returns roughly 7× CondenserSentinel™'s cost per year to a typical 450 MW plant.

A 20–40% reduction in plant downtime, and reduced maintenance costs, returns another 13× CondenserSentinel™'s cost per year to a typical 450 MW plant.
MW
%
$/MWh
ROI MULTIPLE ON ANNUAL COST
19.4×
PAYBACK OF INSTALL, AFTER SUBSCRIPTION
31 days
NET ANNUAL BENEFIT
$3.20M
MWh/YR RECOVERED (EFFICIENCY)
23,652
5-YR CUMULATIVE CASH FLOW, AFTER INSTALL · $15.75M
Gross $3.38M/yr = efficiency $1.18M (23,652 MWh valued at your power price) + avoided downtime $2.20M (estimated).Costs: $174K/yr subscription, $275K one-time install. Efficiency only, without the downtime estimate: net $1.01M/yr, 3.3 mo to recover the install charge.
Quick estimate, a first screen and not a plant result: 1% of generation recovered and valued as extra output at your power price, plus an avoided-downtime benefit estimated at 13/7 of that (industry estimates of a 1–3% heat-rate improvement and a 20–40% reduction in downtime). Net and payback include the $174K/yr subscription and the $275K one-time install charge. CondenserSentinel™ quantifies the real number.Get your plant's real number →

Avoid costly damage by catching problems early.

Start with an assessment of the data you already have. No new hardware. ~90-day pilot. Documented ROI.
  • AVEVA
  • Bionetics
  • AES
  • DiPhyx
  • AWS
EPRI'S OPEN POWER AI CONSORTIUM NAMED USING DATA ANALYTICS TO INFORM CONDENSER MAINTENANCE A TOP-4 AI USE CASE