The cost of unplanned downtime in power generation plants
Unplanned downtime in power generation plants is among the most expensive losses in the plant because a single failure, such as forced outages from boiler, turbine, or auxiliary failures, can stop the flow, not just one asset. The true cost pairs lost contribution margin with emergency labour and expedited parts, and is usually several multiples of the repair itself.
What drives downtime cost in power generation plants
- Forced outages from boiler, turbine, or auxiliary failures.
- Outage overruns that extend lost generation.
- Balance-of-plant failures (pumps, fans, mills) that derate the unit.
- Deferred work raising forced-outage risk.
The failure modes behind it
- Forced outages from boiler, turbine, or auxiliary failures.
- Outage overruns that extend lost generation.
- Balance-of-plant failures (pumps, fans, mills) that derate the unit.
- Deferred work raising forced-outage risk.
Size it for your plant
Use the free unplanned downtime cost calculator with your own lost margin per hour to estimate the annual cost, then see how to calculate it properly.
Ranges on this page are practitioner estimates drawn from operational experience across heavy industry, provided for orientation. Your actual figures will differ. The Diagnostic measures them against your own CMMS and downtime data.
Frequently asked questions
Why is unplanned downtime so costly in power generation plants?
How do I estimate downtime cost for my site?
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