What is Fatigue Monitoring?

Fatigue monitoring is the process of continuously tracking the condition of critical equipment—such as boiler components—in industrial plants to detect signs of material fatigue caused by temperature, pressure, and cyclic mechanical stresses over time.

What is the Fatigue Monitoring System (FMS)?

FMS is an advanced digital solution from Siemens Energy that continuously monitors the fatigue and creep status of critical boiler components in real time, helping operators optimize maintenance, extend asset life, and prevent unexpected failures.

How does FMS assess fatigue in boiler components?

FMS uses real-time temperature and pressure data from the plant’s Distributed Control System (DCS), applies EN 12952 Parts 3 & 4 standards, and calculates creep and low-cycle fatigue through proven algorithms.

Which boiler components can FMS monitor?

FMS typically monitors high-pressure drums, separators, superheater/reheater manifolds and headers, branches, spray water injectors, gate valves, and can easily scale to cover up to 88 components per boiler.

Is Fatigue Monitoring System compatible with any boiler type?

Yes, FMS is versatile and supports vertical/horizontal HRSGs (with or without supplementary firing), conventional fired steam generators, and biomass boilers, using drum-type or Benson once-through evaporator designs.

Does Fatigue Monitoring System require a plant shutdown during installation?

No. FMS installs on a technology server, supports hot commissioning in as little as six months, and does not require unit disassembly or lengthy outages.

Is Fatigue Monitoring System certified for compliance?

Yes, FMS is TÜV-SÜD certified out-of-the-box, providing verifiable, standard-compliant calculations and full transparency for regulatory or audit requirements.

Can Fatigue Monitoring System help save costs on maintenance?

Absolutely. FMS supports early detection of fatigue risks, enables cost-effective inspection planning, reduces unnecessary downtime, and helps prevent expensive repairs—often delivering ROI in under three years.

Can I integrate Fatigue Monitoring System with other digital systems or platforms?

Yes, FMS integrates with Siemens Energy’s Omnivise ecosystem, supports MEP.Core, OPC UA, and cloud-based platforms like AWS IoT, ensuring secure interoperability and unified monitoring.

How do I get started with Siemens Energy’s Fatigue Monitoring System?

Contact Siemens Energy’s experts for a consultation, demo, or site assessment. They will guide you through implementation, customization, and ongoing support to ensure maximum plant reliability and value.

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.

Key benefits include:

Fully automated, real-time fatigue assessment—every day
Certified TÜV-SÜD monitoring ensures traceable, industry-compliant results
Optimized inspection planning and smarter maintenance strategies
Early warning of fatigue risks for preemptive action
Long-term protection for your valuable boiler assets

With fatigue monitoring, you transform operational data into enhanced durability, safety, and efficiency, empowering you to optimize your power plant performance and minimise risk.

Fatigue monitoring animation that explains key benefits of FMS, turning operational data into durability, safety, and efficiency for the power plants

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.

Illustration with screenshots of the Fatigue Monitoring System showing the main features for protecting boiler assets.

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.

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"In 2022, the Fatigue Monitoring System was implemented at the GuD2 power plant for In-fraLeuna GmbH. InfraLeuna sees FMS as a good opportunity for continuous monitoring of components and for simplifying its inspection efforts."

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.