The Surge in Power Demand
The power industry is experiencing unprecedented growth, largely driven by data centers and artificial intelligence (AI) applications. This rapid expansion presents opportunities for utilities, equipment manufacturers, and the broader generation ecosystem. However, it also introduces challenges, as stakeholders must scale operations and engineering resources efficiently.
Seth Harris, North America Power Business Growth Director at Emerson, emphasized in a recent industry podcast that adapting to this evolving demand requires both expertise and strategic planning. With 20 years at Emerson across multiple roles, Harris offers deep insight into the changing needs of modern power plants.
Data Center Impact on Industrial Automation
Data centers are fundamentally transforming power generation strategies. Utilities must now reconsider operational priorities, as AI-driven workloads increase demand variability. Harris noted that turbines, heat recovery steam generators, control systems, valves, and instrumentation manufacturers all face unprecedented order volumes.
Moreover, companies cannot simply expand production; they must also upgrade engineering processes and maintain quality across complex projects. In addition, the speed of deployment has become a critical factor, as rapid supply of electricity is essential to meet growing AI-driven demand.
Extending Plant Lifecycles
One significant area requiring attention is the operation of existing power plants. Facilities previously scheduled for retirement now face extended service life due to AI-driven load demands. Harris highlighted that maximizing efficiency and reliability has become a priority for these aging assets.
Upgrading older facilities often involves integrating modern control systems and measurement technologies. “Technology has advanced significantly since these plants were first built,” Harris explained. Many plants no longer operate as baseload units but provide peaking or backup capacity, necessitating adaptive control solutions. Emerson continues to lead in retrofitting legacy plants to optimize performance.
Leveraging Modern Technology for Upgrades
Over the past two decades, power generation technology evolution has enabled significant plant upgrades. Emerson applies innovations developed for new-generation plants to older facilities that may be 40–50 years old.
For instance, radar-based high-pressure steam drum level measurement improves accuracy in boiler control. These precise measurements enhance reliability during startup and shutdown cycles, especially when equipment operates near pressure and temperature limits. Such upgrades ensure safety while maximizing output efficiency.
Integrating Artificial Intelligence in Power Systems
AI serves a dual role in the power sector: driving demand and enhancing operational efficiency. Emerson leverages existing field instrumentation and valve diagnostics to feed AI-based control systems.
Modern devices provide data on calibration status, flow distribution, and component condition, yet many remain underutilized. Integrating these signals with AI allows operators to anticipate maintenance needs and optimize control strategies. Emerson’s Ovation 4.0 platform, featuring the Virtual Advisor, captures expert operator knowledge and delivers actionable insights to less experienced personnel. Harris described it as empowering AI with the expertise of top operators.
Supporting Diverse Generation Assets
While gas-fired and nuclear facilities often make headlines, diverse energy sources will remain essential. Emerson supports various plant types, including wind, solar, gas turbines, and coal, providing integrated solutions across generation and distribution networks.
Ovation Green enables utilities to optimize entire grids, particularly as large data centers introduce dynamic load requirements. This comprehensive approach ensures reliable power delivery and efficient management of multi-source generation portfolios.
Addressing Workforce Challenges
The industry also faces significant workforce issues, as experienced operators retire and skilled personnel diminish. Technology helps bridge this gap through intuitive interfaces and intelligent guidance. High-fidelity plant simulators allow operators to train effectively before facilities go live.
Ovation 4.0 redesigns the human-machine interface with consumer electronics-inspired principles, including screen prompts, diagnostic alerts, and priority-based alarm management. These features help new operators leverage retired experts’ experience while simplifying daily operations.
Execution is Key
Ultimately, the power industry must execute strategic plans effectively. Clear demand signals and future visions exist, but transitioning current capabilities to meet future needs requires careful planning.
Harris emphasized Emerson’s role as a long-term partner, offering equipment, engineering support, project management, and lifecycle assistance. This integrated collaboration ensures utilities can meet AI-driven electricity demands through the 2020s and into the 2030s, aligning with the growing digital economy.
Application Scenarios
- Legacy Plant Upgrades: Retrofitting turbines and control systems to extend operational life.
- AI-Optimized Operations: Integrating sensor data into predictive maintenance and efficiency dashboards.
- Data Center Load Management: Ensuring rapid power response for dynamic, high-density workloads.
- Workforce Enablement: Using advanced HMI and simulation training for new operators.