Shock Pulse Method: Innovation for efficient boiler cleaning

Safety is the top priority. Each Shock Pulse Generator has its own PLC controller with touchscreen operation. This monitors all important process variables and shuts down the equipment immediately if there are any deviations from normal operation. Different variants are possible for data exchange with the DCS as well as with the manufacturer or maintenance company.

The Shock Pulse Generator system consists of the following components:

• • Shock Pulse Generator: mounted on the boiler outer wall. The Shock Pulses are guided into the inside of the boiler through a connecting piece or a manhole using a discharge nozzle
  • Control cabinet: controls the Shock Pulse, connected to the distributed control system (DCS)
  • Pressure regulating units: reduce the cylinder pressure of natural gas/methane, air and nitrogen
    to 40 bar
  • Valve panel: assembly consisting of valves, pressure transmitter and terminal box
  • Air compressor unit: supplies combustion air; integrated into SPG LogView

The gas supply for the Shock Pulse Generators can be easily realised using individual cylinders or small bundles of 200 bar. The tubes to the generators have a minimum nominal diameter of 10 mm and a maximum line pressure of 40 bar (e.g. pipes V2A, nominal inner diameter DN10, nominal pressure PN63). A small compressor can also be used for natural gas if an existing grid connection is available. The use of an air compressor unit is preferred for the air supply. In addition, a single nitrogen cylinder is required for the gas spring chamber of the piston in the Shock Pulse Generator. The SPG is installed on the outside of the boiler wall. The SPG is suspended as a sliding installation on a rail and held in position by a spring mounting on the machine flange (DN200 PN16 or DN250 PN10). The suspension reduces the force generated by the Shock Pulse Generator on the boiler wall. The discharge nozzle is positioned such that it is flush with the boiler inner wall. The Shock Pulse Generator can be mounted horizontally on the boiler wall or vertically on the boiler ceiling.

• CE certification according to the Pressure Equipment Directive (PED)
• High-pressure-resistant construction
• Installation of the gas supply line in accordance with local regulations
• The ignitable mixture is only mixed inside the pressure-resistant Shock Pulse Generator
• The PLC controller monitors important process data and shuts down the Shock Pulse Generator if there is a deviation from the set values
• Automated; no operation or intervention by personnel necessary
• Before each Shock Pulse, an alarm occurs by means of a signal horn and flashing light
• The volume of the pulse outside the boiler is below 135 dB (A); for a short time
• No leakage of boiler tubes due to pressure wave
• No use, transport or storage of explosives (dynamite)
• PROFIBUS, MODBUS or 24 V DC hard-wired

As part of the growing Industry 4.0 standardisation, Explosion Power GmbH has launched the internet platform SPGLogView and the remote access hardware SiteManagerTM for the entire Shock Pulse Generator fleet. The new hardware has been installed as standard for all new projects since March 2016 and can now be retrofitted for existing installations.

Control cabinets equipped with SiteManagerTM send the operating data of the connected Shock Pulse Generators to GateManagerTM daily. This is located in the headquarters of Explosion Power GmbH (see diagram above). Each SiteManagerTM communicates exclusively with the GateManagerTM it was connected to during set-up. The operating data is made available to the respective customer and partner via SPGLogView. Remote support can also be provided by remotely accessing the HMI of a connected control cabinet. Remote access is only possible with the prior consent of the customer.

With Module D of the Pressure Equipment Directive (PED 2014/68/EU), which is regularly audited by the appointed body for pressure equipment (DEKRA Automobil GmbH), Explosion Power GmbH demonstrates the application of a corresponding quality management system.

Quality assurance includes measures before, during and after production, including their frequency.

In terms of content, the requirements for the QM system set out by the PED are based on the relevant requirements of a certification according to DIN EN ISO 9001, supplemented by product-specific requirements as specified in Annexes I and III to the PED.

The requirements of our QM system go beyond those of DIN EN ISO 9001.

Predictable preventive maintenance: fewer active interventions are required by operating personnel on the unit or in the control cabinet. Lower maintenance costs due to savings in working hours and spare parts.

Efficient gas consumption: stoichiometric combustion reduces CH₄ consumption by more than 40%.

Safe operation without pure oxygen: avoiding the use of pure oxygen (O₂) increases safety, lowers costs and reduces workload (no need to provide or replace oxygen bundles).

Reliable supply of auxiliary systems: purge air is generated by a purge air module, while compressed air is provided by a compressed air supply unit.

Greater adaptability: greater adaptability to individual boiler conditions thanks to only two different SPGr sizes compared to four in the EG series.