Yes, AI can predict corrosion in power generation assets with exceptional precision. CorrosionAI applies machine learning to forecast boiler tube corrosion, steam turbine blade degradation, and heat recovery steam generator (HRSG) failures. By analyzing water chemistry, flue gas composition, thermal cycling patterns, and historical inspection data, the platform enables operators to shift from reactive tube replacements to predictive maintenance — reducing forced outages that cost $500,000 to $1.5 million per day.
Critical infrastructure faces unique threats that demand proactive monitoring and maintenance
Unplanned outages cost millions per day - predictive maintenance is critical for continuous operation
High-temperature corrosion, erosion, and stress cracking threaten heat recovery steam generators and boilers
Microbiologically influenced corrosion and scaling reduce efficiency and increase maintenance costs
ASME, NERC, and environmental regulations require continuous monitoring and documentation
Comprehensive protection powered by advanced AI and machine learning
Monitor waterwall tubes, superheaters, economizers, and evaporators for corrosion and erosion.
Protect steam turbine casings, condensers, and cooling water systems from corrosion losses.
Track piping systems, heat exchangers, storage tanks, and auxiliary equipment.
Automated documentation for ASME inspections, insurance requirements, and audits.
Real-world performance metrics from power plants worldwide
Across power generation globally
For boiler and condenser corrosion
Long-term asset lifecycle planning
Mission-critical uptime guarantee
Protecting critical assets across all generation technologies
| Metric | Value | Source |
|---|---|---|
| Boiler tube failures as % of forced outages | 40–60% of outages | EPRI |
| Average cost of a forced outage (500 MW plant) | $500K–$1.5M/day | IEA |
| Corrosion-related maintenance (% of total O&M) | 25–35% of O&M | NACE/AMPP |
| Average boiler tube replacement cost per event | $200K–$800K/event | Power Engineering |
| HRSG tube failure rate (combined cycle) | 2–5 leaks/unit/yr | EPRI HRSG |
| Flow-Accelerated Corrosion (FAC) incident rate | ~30% of piping failures | EPRI FAC |
| Global power plant corrosion market | ~$5.2B/year | Mordor Intelligence |
| Carbon steel wastage rate (high-temp fireside) | 1–5 mm/yr (coal) | EPRI / B&W |
Join leading utilities and independent power producers using CorrosionAI to prevent failures