How effective is boiler cleaning in my power plant? – Since every power plant is complex and unique, this question can never be answered based on individual measurements. For Explosion Power, the answer lies in a customized boiler analysis. In our current blog post, we take a closer look at this topic: We interviewed Simon and Martin from the “Boiler Process Improvement” department to find out what makes a boiler analysis, how it interacts with the operation of the Shock Pulse Generators (SPG), and how it can improve plant efficiency and profitability.
Photo: Simon Knellwolf, Department Boiler Process Improvement at Explosion Power
What is a boiler analysis?
Simon: A boiler analysis is the foundation for optimizing boiler cleaning and, consequently, boiler operation. Based on a digital twin and current plant data, the boiler operation is assessed, and the settings of the Shock Pulse Generators are adjusted accordingly. With this innovative approach, we can sustainably improve boiler cleaning and identify further optimization potentials in the plant.
Martin: Boiler analysis make the data from the plants readable in the first place. Without a boiler analysis, the various measurements — temperatures, pressures, flow rates, etc. — are only related with great effort. Additionally, each plant looks different, and the plant data is transmitted in very different formats. We structure the analysis in such a way that it becomes very simple, allowing us to support our customers transparently and with high quality.
What benefits does the customer get from a boiler analysis?
Simon: With the help of the boiler analysis, targeted operational optimization of the Shock Pulse Generators can be carried out, thereby improving plant efficiency and profitability. Additionally, the analysis can provide for example the basis for longer travel times and the reduction of downtime. Here’s what lies behind that: Boiler operating data changes over time due to fuel composition, load variations, degree of fouling, etc. Therefore, we always recommend that customers adjust the SPG operation to the current plant operation and condition. For this, we use SPG intensity levels that are specifically determined for each plant. The appropriate intensity level to set depends on the current plant operating parameters. Thus, the cleaning performance of the SPGs is optimally adapted to the boiler condition. Since “intensity regulation” is a new concept, Explosion Power has filed a patent application.
Martin: Ideally, these intensity levels will be implemented in the customer’s process control system (PCS) to automatically adjust the SPG settings. At the same time, we provide customers with detailed feedback on operating behavior, the quality of measurement points, and deviations from normal operation. For this, we use not only the measured values but also calculated values such as heat transfer coefficients, efficiencies, balance results, cross-comparisons, specific key figures, etc.
What are the individual steps of the boiler analysis?
Simon: First, the P&IDs and boiler drawings provided by the operator are analyzed, the boiler model is created, and a list of the required measurements is derived. The required measurement data is then periodically transmitted to us by the plant operator. Afterwards, these are imported into our proprietary database, analyzed, and presented in customerspecific diagrams. During this process, the proposed intensity Level settings of the SPGs are checked, and the Boiler Operation is closely examined.
What does the plant operator need to do?
Simon: The plant operator must provide us with the necessary information about the plant, such as drawings and P&IDs. Additionally, they should periodically provide operational data and allocate time for exchanges with us.
How is the data analysis carried out specifically?
Martin: For the analysis, we use the process data platform OpenPi (for detailed information: www.explosionpower.openpi.com). Each plant has its own boiler analysis stored on this platform, which the customer can also view with their own login. The plant data is imported either manually or automatically, with no data connection to the process control system (PCS) during automated import. Subsequently, the calculations are performed and the results are compared with the operating data of the Shock Pulse Generators. During this process, the settings for the intensity levels are determined and aligned with the operation of the SPGs.
How does Explosion Power provide feedback?
Martin: We hold regular video conferences with our customers to discuss the results of the analysis. During these meetings, we show which operation or intensity level settings we recommend. At the beginning of the analysis, this can be done weekly as needed; for experienced customers, it can also be done monthly or quarterly.
How is data protection ensured?
Simon: The plant operator transmits the required measurements to Explosion Power and/or the local distributor. All transmitted data is treated as strictly confidential by Explosion Power and the local distributor. The analysis results are discussed exclusively with the respective customer.
Martin: In anonymized form, we use insights from the boiler analysis to further optimize our products. Without the explicit consent of the customer, the data and analysis will neither be shared nor published.
Simon: Speaking of publications – with the consent of the respective customers, we have already published several interesting technical articles at various conferences in the past, where we report on the results of our work.
How many customers are you currently supporting with boiler optimization?
Simon: Currently, we’re supporting over 20 customers who are using a total of around 100 SPGs. Due to the high level of interest, we expect these numbers to increase rapidly.
If you want to learn more, contact us here.
