Operational data is available, but potential remains untapped. Without intelligent evaluation, optimisation is impossible.
Boiler fouling is only detected when it is too late, resulting in costly downtime.
Manual interventions rely on individual key personnel and cannot be scaled.
BPI generates continuous data evaluations from a digital boiler twin to optimise your processes. The result: a feedback loop that increases your plant’s efficiency daily.
The boiler model documents the configuration of your plant – from the design of the boiler passes to the measuring points. All relevant measured values are recorded and calculated, as well as visualised and analysed on the cloud platform openpi.com. This data transparency forms the basis for implementing targeted optimisation measures.
We analyse the P&IDs and boiler drawings you provide to create an overview of the required measurement values. This data is collected regularly, imported into our database and displayed in customer-specific diagrams. It can be used to review intensity levels and make precise adjustments – for optimal boiler operation.
Our evaluation reveals how operating times can be extended and downtimes reduced. Since boiler operating data changes due to factors such as fuel composition and fouling, we continuously adapt SPG operation to the current operating conditions. The result: greater efficiency and reliability in long-term operation.
The SPG intensity levels are precisely tailored to the specific requirements of your plant. In ideal cases, we implement the steps directly in your distributed control system (DCS), meaning that adjustments are made automatically. We also analyse the mode of operation, measuring point quality and deviations – based on measured and calculated values such as efficiency, balance results and heat transfer coefficients. This allows us to optimise the performance of your boilers sustainably.
Through continuous optimisation, your plant performance increases measurably.
Reduced downtime, increased availability, improved planning reliability.
Data-driven decisions instead of gut feeling – measurably higher efficiency.
Your data remains secure. Transparent evaluations and regular feedback loops.
Dedicated support, regular exchange, long-term partnership.
The example illustrates a boiler evaluation used to determine the required cleaning intensity for achieving the target temperature.
The boiler was originally equipped with a Shower Cleaning System (SCS). Such wet-cleaning systems remove deposits in a very short space of time, leading to extreme temperature fluctuations. The diagram exemplifies the resulting sawtooth profile of the flue gas temperatures.
The empty passes were subsequently fitted with Shock Pulse Generators. Since then, the flue gas temperature upstream of the final superheater has been significantly lower and stable. Furthermore, overall output has been increased.
Our evaluations identified the weaknesses and operational limits of the existing systems. Following the retrofit, output was stepped up incrementally, with cleaning intensity adjusted accordingly based on the ongoing data analytics.
Find further details here: Case Study CH-Bern
Data import is carried out either manually or automatically. However, automated import does not involve a direct connection to the Distributed Control System (DCS).
Our patented Shock Pulse technology effectively prevents deposits in large boiler plants – from membrane tube walls to tube bundles. The result: longer operating times, higher availability and lower maintenance costs. With over 1,500 installations worldwide, we ensure permanently clean boiler areas in waste, industrial and power plant facilities.
Optimise your boiler system with targeted measures.
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