Boiler Diagnostics
Assess flexible operating modes, detect leaks at an early stage and optimise combustion and soot blow-off.
This will help you reduce downtime, increase efficiency and ensure planning reliability.
Transparency in boiler operation – from condition to action
The safe, efficient and reliable operation of steam boilers, particularly when using solid fuels and under variable operating conditions, requires insight into the condition and operating mode of the plant. Only in this way can the effects on service life and cycle time, as well as the efficiency of the combustion process, be reliably assessed, thereby laying the foundations for economic and technical success.
Digital solutions in the context of boiler diagnostics aim precisely at this goal – assessing the effects of flexible operating modes, removing deposits in a targeted manner, identifying leaks early and reliably, and optimising the combustion process. This takes the pressure off the operating team and provides reliable guidance on necessary measures, allowing time for repairs and providing a sound basis for decision-making.
Lifetime monitoring of thick-walled boiler components
Thick-walled components in steam generators and waste heat boilers are among the most heavily loaded components and are critical to operational safety. Particularly in flexible plant operations involving numerous start-ups, the stresses resulting from cyclic fatigue typically far exceed the design specifications. SR1, as a certified tool accepted by TÜV in many areas, delivers results that can be validated at any time and serves as an important basis for assessment for operators, approved inspection bodies, and competent authorities to determine test cycles and scopes in a targeted manner.
Soot blowing
The use of solid fuels in the boiler generally leads to gradual fouling of the heating surfaces and, consequently, to a decrease in efficiency. Determining the optimal time for cleaning based on the boiler’s condition and other operational parameters—whether through recommendations or a “closed-loop” system—is key to cost-efficient operation, extended service life, and gentle cleaning. Fuel-related factors are specifically taken into account, and the integration of third-party systems and sensors—particularly within the combustion chamber—is also possible.
Boiler Leakage Detection
Boiler leaks are the most common cause of unplanned downtime in combustion systems. The solution’s key feature is the early and reliable detection of leaks while avoiding false alarms. Thanks to early and reliable information, consequential damage can be significantly reduced, planning for corrective measures can begin early, and the extent of damage can be limited—as a result, the plant is back in operation faster with reduced repair costs. The system typically relies on existing acoustic sensors, which are specifically analyzed using artificial intelligence and statistical methods to ensure reliable detection.
Combustion Optimization
Modern solid-fuel combustion systems are equipped with a wide range of actuators to accommodate varying fuel properties, operating conditions, and load requirements. Efficient operation must ensure the optimized use of these control levers at all times, even when there is significant variation in the fuels being used.
PiT Navigator, based on model predictive control, anticipates control actions based on the plant’s current state, the current fuel, and current operating conditions, thereby reducing control deviation while increasing throughput—and thus directly improving the plant’s economic efficiency. Additional constraints, such as emission limits that must be met, can also be taken into account in the optimization process.
