Fatigue Monitoring System: proactive protection for your boiler assets

Critical boiler components in modern power plants operate under relentless stress - from high temperatures, pressures, and frequent load changes. Over time, these extreme conditions can degrade materials and threaten asset integrity, creating risks for downtime, costly repairs, and safety incidents.

With over 20 years of experience and more than 120 projects worldwide, Siemens Energy offers a robust and scalable Fatigue Monitoring System (FMS) that empowers you to take control of boiler reliability and performance.

Siemens Energy’s Fatigue Monitoring System (FMS) delivers a smarter, data-driven approach, applying proven EN 12952 Parts 3 & 4 standards to continuously monitor the actual condition of your boiler components in real time. It calculates creep and low-cycle fatigue online, transforms data into visual, actionable insights, and auto-generates clear monthly reports—enabling proactive decision-making and truly reliable protection.

Today’s power plants must meet rising efficiency targets and operational flexibility. This exposes vital boiler components to higher temperatures and frequent cycling, accelerating fatigue and creep damage.

FMS provides smart, online monitoring, accurately quantifying real-time fatigue for all critical components and helping you:

• Act fast on actionable data, not assumptions
• Optimize inspection cycles and reduce unnecessary downtime
• Make maintenance decisions based on transparent, data-driven insights
• Achieve cost-effective, safe, and flexible operation

By equipping your plant with a Fatigue Monitoring System, you gain the clarity and confidence to make smarter, faster decisions and protect your most valuable assets.

Watch the video: Fatigue monitoring system increases performance for your bolier component.

Unlocking these advantages starts with the advanced, user-driven features that set the Fatigue Monitoring System apart. Explore how each capability works together to maximize reliability, streamline operations, and keep your boiler assets protected.

Siemens Energy’s Fatigue Monitoring System (FMS) delivers a powerful blend of detailed fatigue insights, automated reporting, and flexible adaptability. 

FMS's intuitive interface brings all calculation results to your fingertips:

• Transparent overview and drill-down for each monitored component
• Lifetime predictions and creep fatigue statistics
• Number of cycles remaining before crack initiation
• Stepwise value tables for granular insight
• Trend graphs for visualizing temperature/live steam or load/fatigue relationships

Receive monthly, configurable reports that summarize all key findings, support compliance documentation, and simplify strategic planning. For advanced users, FMS brings integrated finite element stress modeling for “what-if” scenario analysis and precision fatigue prediction.

FMS adapts to your operation, whether you run:

• Vertical or horizontal HRSGs (with/without supplementary firing)
• Conventional fired steam generators
• Biomass boilers 

Monitor:

• Boiler drums, separators, headers, manifolds, branches, injectors, and gate valves
• Systems from drum-type to once-through (Benson) evaporators

You can scale, from standard HRSG coverage to intensive custom monitoring for complex plants. FMS grows with your needs. 

At the GuD2 power plant, FMS tracks high-pressure components to standard DIN EN 12952, delivering real-time data, automated reports, and a step-change in inspection efficiency for InfraLeuna. Integrated with Omnivise T3000 since 2022, FMS has enhanced operational safety and performance.

• Certified by TÜV-SÜD: Third-party validation delivers full transparency and compliance; no extra fees or complexity.
• Fleet-proven: Trusted on more than 100 units worldwide, with substantial ROI from downtime avoided and maintenance optimized.
• Integrated & efficient: Works seamlessly with Omnivise and existing digital systems; lowers setup time and costs.
• Easy to use, empowering teams: Unified access enables fast, informed, and proactive responses. 
• Maximized alue: Reduce inspectivon costs, avoid surprise damage, and boost plant reliability without compromising your budget.