Design, manufacture and supply of equipment, construction and installation, warranty and maintenance of energy facilities.

Boiler cleaning systems

 

Centre of Competence  for On-load Boiler Cleaning

Headquartered in the  German  town  of  Wesel,  Clyde Bergemann   GmbH  is the  competence centre  for  on- load   boiler   cleaning   within   the   Clyde   Bergemann Power Group. The company’s typical fields of operation include thermal  energy  conversion processes  based  on coal, waste and/ or biomass. For over 70 years, we have focused  our work on the development and production of  efficient  solutions  for  on-load  cleaning  of  heating and  reaction  surfaces.  We offer an extensive  range  of cleaning  devices specifically designed  for the  different cleaning   requirements  within   a   boiler   by  applying various cleaning methods and nozzles as well as nozzle arrangements.

 

Technology leader with process expertise

As a  pioneer  in  the  industry,  we  play  a  vital role  in shaping   cleaning  technology.   As  such  we  were  the first  in  the   market   successfully  applying   water   for furnace  cleaning.  Likewise, we were  quick to spot  the advantages  of  demand-driven  boiler  cleaning   which is performed according  to  the  actual  deposit  situation and  not  following  a  fixed cleaning  scheme.  A whole new  philosophy  has evolved out  of the  advantages of demand-driven boiler  cleaning.  We  call this  “SMART CLEAN”.

 

Complete Solutions  & Life-long Support

We construct  and  deliver complete  solutions  in which hardware,  software,   shut   off  and   regulation   valves, as  well as  controllers,  are  perfectly  coordinated.  Our diligence, which is applied by our experts in the design of boiler cleaning systems, is also apparent during installation,  commissioning  and  servicing  throughout the service life of our technology.

Your Benefits:

 

  • Extended boiler availability
  • Increased boiler efficiency
  • Controllable deposit build-up regardless of flexible boiler operation and changing  fuel mixture or varying fuel quality
  • Effective and efficient boiler cleaning
  • Professional consultation  in all boiler cleaning matters
  • Procedural expertise from more than  60 years of experience in power  plant boiler cleaning solutions
  • Comprehensive service
  • Training for your employees by our own experts

Areas of use

 

Our offer for power plants

 

Careful Engineering  – The Key for Effective  Boiler Cleaning

Every system,  every deposit  build-up  is distinctive and requires comprehensive design planning. Decades of experience in a wide range  of applications showed  that only careful design – as sketched  as an example  in the following – will lead to the best cleaning results.

 

Choosing the Right Cleaning System

The chemical composition  of the  fuel influences  the formation  of slagging and fouling. The more detailed the   information   available,  the   better   the   suitable cleaning  device or combination  of different  devices for a coordinated overall system can be selected. Further selection factors we consider are the boiler design  and  specific design  parameters like flue gas temperatures and steam parameters.

Factors of Success for Cleaning with Steam or Air

The choice of parameters of the cleaning system

Economic arrangement of the  selected  sootblowers is also important. The sootblower should provide complete coverage of the contaminated tube surfaces whilst  avoiding  overlaps  to  prevent  the  danger   of damage from overcleaning.  The sootblower cleaning range  must be verified depending on the geometries of the surfaces to be cleaned, the pitch and the superheater package  height.

Selection of the  right nozzle depends on the  degree of   the   deposit   formation.    The  decision   for   the nozzle   shape,   nozzle   diameter,  application   angle and blowing  pressure  is derived from this. The CFEIII nozzle with a specific nozzle geometry was developed for the  extreme  cleaning  requirements of the  black liqour recovery boilers.

We use self-developed  and  scientifically verified engineering software  to ensure design planning quality. This consistent  approach makes  every design  objective and can be replicated.

Fit for Purpose Technology Designed from Experience

Standard-Compliant  Desig

Our  on-load   boiler  cleaning   systems  correspond to national and international safety provisions and our company   is  DIN ISO 9001   certified.  Also  important to us is the  safety of power  plant  employees  who  are responsible  for handling  sootblowers, therefore we pay close attention to details. For example, we only use bolts made  of standard-compliant materials for secure screw connection of the steam-carrying  lance tube.  Particular safety-requirements can be covered by special designs.

Durable Assembly

As the  sootblower travel length  increases,  the  lance or blowing tube‘s weight imposes huge forces. To limit bending  tension,  these  tubes  are  designed  in multiple parts and with different  tube  wall thicknesses.  The first partial tube has the largest wall thickness to ensure structural  stability.

Generally, we determine material composition  and wall thickness for lance or blowing tubes specifically for each installation to match  the application  conditions and the operational frequency  of  each  individual  sootblower. This attention to  detail  will provide  lifetime and  cost benefits for our customers.

Avoiding Condensate Corrosion

Incorrect  sizing  of  the  internal  steam  feed  tube  can have expensive consequences. If the feed tube  outlet  is positioned too far from the boiler wall opening, the steam can condense in the feed tube  whilst the sootblower is not in operation. Consequence: Condensate continually drips on the inner lance tube wall, eventually leading to corrosion.

Clyde Bergemann  feed  tubes  always terminate within the lance tube  after the sootblower front plate,  so that the  heat  emitted  by the  boiler wall opening  is used  to prevent condensation.

Safety

Generally,  all steam-carrying   components are  discon- nected  from the  drive. This ensures  the  safety of your employees  and protects  the sootblower from expensive damage.

Protection  of Mechanical Components

Drive unit suspension  is selected  to balance  the weight on several suspension  points. This prevents  overloading of  mechanical  components, e.g.  by  a  single  spindle, from the very first operation.

The Complete Range of Sootblowers for Cleaning with Steam or Air


 

For Travels up to 20 Meters

SMART RSG – Maximum Flexibility
for On-load Cleaning of the Convection Area

 

Lower Steam Consumption, Lower Erosion – While still Achieving an Enhanced Cleaning Effect

Deposits in the convective heating areas tend to have an uneven distribution.

The use of conventional  cleaning technologies can lead to the following issues: Insufficient cleaning of badly affected  areas  due  to  cleaning  parameters set  to  less deposited areas;  tube  wear  in zones  with  less or  no deposits due to intensified cleaning of heavily deposited areas.

The non-uniform fouling distribution requires a corresponding flexibility from  the  on-load  boiler cleaning system to achieve the best and most economic cleaning results. Certain fuels have a tendency  to build- up strong deposits which push conventional  retractable sootblowers   to  their  limit. This situation  encouraged us to the  further  development of the  sootblower to a selective and efficient working cleaning device.

The  SMART  RSG is a  retractable  sootblower  with  a unique  dual-motor design  which  allows  independent and variable traversing and rotational speeds. The speeds can be varied at any time.  All parameters required  for cleaning  – traversing  speed,  rotational  speed,  blowing pressure,  blowing  angle  – can be set as required  with a flexible combination. This leads to different  cleaning intensities that  best match the fouling condition.

 

Freely adjustable cleaning parameters of SMART RSG


traversing speedfreely adjustable
rotational speedfreely adjustable
blowing pressurefreely adjustable
intensive cleaningfreely adjustable
repeat cleaningfreely adjustable
oscillation yes/no freely adjustable

Your Benefits:

 


  • Cleaning parameters can be adjusted  to match the
  • fouling condition
  • SMART RSG minimises erosion
  • SMART RSG economically uses steam or air –
  • cleaning media savings of up to 60% Extended boiler availability
  • Improved heat transfer
  • Increased boiler efficiency
  • When combined  with diagnostics/analysis modules of the SMART CLEAN platform, it is turned  into a fully automated on-load cleaning system that  can be seamlessly integrated into your control system

 

Factors of Success for Cleaning With Water


Water Jet Quality is Vital

To achieve the water jet quality required for successful on-load boiler cleaning, several parameters must be perfectly aligned with each other and to slagging and fouling.

Nozzle geometry and nozzle diameter, as well as the blowing pressure, are essential factors that determine the water jet quality. In the cleaning operation, the water impact angle, the water volume and the size of the covered area must match the intensity and characteristics of the deposit. By varying the water jet speed, the impact time is adjusted to the fouling intensity.

Two Cleaning Principles When Using Water

  • The wall blower F149 achieves its cleaning effect via the peak impact pressure. The kinetic energy of the blowing jet is converted to pressure energy when escaping the nozzle.
  • The SMART  Cannon  and  the Shower-Clean     System    SCS do not achieve their cleaning effects by peak impact pres- sure. Water  penetrates the deposits‘ pores,  vaporises due to   direct   heat   transfer,   and leads   to   a   sudden   increase of volume.  The deposits  then break off.

The retractable sootblower SMART Helix Water  uses a combination  of both cleaning principles.

The Complete Range of Water Cleaning Devices


When Using Coal, Waste or Biogenic Fuels



SMART Cannon

The Most Effective  Method of Furnace Cleaning


Water: a Proven Alternative

The  high  temperatures  in  the  furnace   may  lead  to slagging hotspots. As a specialist for on-load  boiler cleaning,  we have recognised  the potential  of cleaning with water  very soon.  The SMART Cannon  has proven its efficiency in furnace  cleaning around  the world. The assembly is based on two linear drives and a ball-shaped suspension  for the  blowing  lance.  The light,  compact design  is made  for  the  challenging  conditions  in the power  plant.  Each of the  horizontal  and  vertical linear drives is subjected  to quality inspection  with a 100  kg weight before delivery. Load resistance of the drives and uninterrupted current intake of the motor are therefore ensured.

Operation  Principle

Due to  its specially developed  control  technology,  the water  jet  creates  a  meander shaped   pattern on  the side and  opposite  wall. With its horizontal  and  vertical blowing  arc each  of 90°,  a single cannon  can clean a large area  of the  furnace.  The cleaning  configurations can be determined precisely and  repeated consistently. The lance movements are directly and continuously monitored. We  do  not  rely on  monitoring   the  drive unit  alone,   therefore  preventing   uncontrolled water application into the furnace.

To  clean  opposite   walls  at  a  distance   of  up  to  25 meters,  we combine  different  nozzle sizes and blowing pressures.

Unbeatably Efficient

A single  SMART  Cannon   cleans  a  much  larger  area– coloured blue in the above figure – than several conventional   wall  blowers  together –  cleaning  areas coloured white in the above figure.

High Performance,  Compact Design


Your Benefits:


  • Heavy-duty cleaning system suited for the high furnace temperatures
  • Compact  design
  • Cleans areas difficult to access, e.g. hopper, centre wall
  • Cleaning figures can be individually adjusted  to boiler geometry  – simple change  on demand
  • Precise, repeatable water jet positioning
  • Open system to connect  different control systems

SMART Cannon uses a gear with constant  drive force

 

Technical Highlights


Water-Jet Quality: A specifically developed  high-performance nozzle  creates  a concentrated water  jet. A rectifier calms the water  jet at the lance entry. A very precisely designed  nozzle end prevents the water jet from expanding.

Flexible Blowing Figures:The control programme enables precise adjustment of the blowing configuration to match  the  geometry  of the  area  to be cleaned.  Different monitoring  functions ensure blowing figure repeatability.

Protection  of Critical Areas:The control  system  can  ensure  certain  areas  are  excluded  from  water  jet application.Large Cleaning Area and Reliable Flue Gas Sealing:The blowing  lance is mounted in a ball-shaped  suspension  that  gives the SMART Cannon  its large cleaning range while also securely sealing it against the flue gas outlet.

High-Performance  Motor:Moving parts  can  be  blocked  by deposits  at  any time.  The direct  current servo  drive used  also  works  at  a  constant drive force  at  this  resistance, ensuring reliable operation of the SMART Cannon.

Low and Easy Maintenance:Robustly designed  assembly  consisting  of a vertical and  horizontal  linear drive. An individual can perform replacement without  using any pulleys.

 

SMART Shower-Clean  System (SCS) Increased Availability for Waste and Biomass Fired Boilers


Suited for Different  Deposit Characteristics

The SMART SCS uses  water  as the  cleaning  medium. Located on the boiler roof, it removes deposit  from the lower  side,  the  membrane walls, the  pendant heater and superheater surfaces.

The cleaning  nozzle  is mounted on  a flexible, temperature-resistant metal hose. The nozzle enters the boiler guided  by a flange,  which is opened and  closed through an electropneumatic valve.

The surfaces  of deposits  are characterised by different properties.  Their development depends on the chemical composition   of  the  fly ash  in  combination   with  the actual flue gas temperature. The cleaning nozzle forms a water  jet with  a defined  stectrum  of water  droplets and  momentum. To  achieve  successful  cleaning,  it is important that  the frequency of cleaning, water  impact and  quantity  hitting  the  deposits  are specifically set to match  the requirements of each individual plant. When using waste and biomass as the fuel, the cleaning effectiveness  of a water  based  on-load  boiler cleaning system depends on the actual fuel composition  and the consequential deposit  characteristics.  By using different nozzle  designs  and  cleaning  parameters, the  cleaning efficiency can  be  adjusted  to  specific surface  deposit characteristic.

Three Different  Versions are Available:

  • Stand-alone:  recommended  for  open   passes   with small, uniform cross-section
  • Single-Row: recommended for boilers with rectangular cross-section
  • Multiple-Row:  recommended  for  boilers  with complex geometry  – flanges are arranged in multiple rows across the boiler roof, by using a crane runway, different areas can be cleaned.

 

Your Benefits:


  • Increased  plant  availability due  to  reliable  cleaning of the  open  passes which are important for efficient plant operation
  • Stable flue gas temperature
  • Lower   risk   for   high-temperature   corrosion    and reduced  corrosion rate
  • Shorter  revision  period  as  time-consuming manual primary cleaning is almost eliminated
  • The construction  of  SCS allows  cleaning  of  narrow designed  open passes
  • Corrosion protection of the flange by appyling sealing air.

SMART Helix Water For Strong Deposit Build-up at Waste,

 Biomass and RDF Fired Plants

Intensive Cleaning Effect of Water Applied Gently

Fuels with the most variable heating values and chemical compositions are used in incinerators and biomass boilers. Due to their tendency to develop complex deposits, waste, refuse derived fuels and biomass are seen as challenging energy sources. Incinerators and biomass boilers often have low steam parameters for the sootblowers so intensive cleaning is not possible. The strong deposit build-up in the convective area can also mean that conventional steam sootblowers will not work effectively. Consequently, the fouling will continue to increase, causing unplanned downtimes and reduced boiler availability.

Water as the cleaning medium is capable of producing the required intensive cleaning effect. To perform the cleaning as gently as possible on the heat exchanger pipes, spe- cially designed hardware and software components and two gear motors with high-resolution rotary position sen- sors ensure that the SMART Helix Water moves precisely to the cleaning position within the space between the heat exchanger tubes. Water is released for cleaning only. This new cleaning method is also called the “Go-Stop-Clean- Go“ technique. Novel water jet controls guarantee an in- stant build-up and interruption of the water outlet from the pressure-active nozzle. If no cleaning is performed, the entire water flow is used for cooling the retractable soot- blower in a closed cooling circuit.

Only the deposit surfaces are hit by the water and this is solely done at the time of cleaning. Heat exchanger pipes are not thermally loaded and the amount of water poured into the boiler is reduced to a necessary minimum.

Your Benefits:

  • Removal of complex  deposits  in convective  heating surfaces
  • Cleaning with water  without  thermal  loading of heat exchanger  pipes (“Go-Stop-Clean-Go“ mode)
  • On the spot starting and stopping  of the water jet for cleaning minimises the amount of water  poured  into the boiler
  • Even narrow  passes are cleaned reliably
  • Flue gas temperature remains in the rated range
  • Extension of boiler availability
  • More  flexibility as  to  the   fuel  mix  since  cleaning intensity can be adjusted  to the  fouling condition  at any time
  • No steam required for cleaning

 


Rapping Devices – Gentle Removal of Deposits

Without Use of a Cleaning Medium


Especially long-stretched boiler passes such as those found in waste incineration plants, can be cleaned with the help of a rapping device. They can be applied to

We develop and produce pneumatic rapping devices in cooperation with Norgren company.
remove deposits from the heating and reaction surfaces
of the convection area and economisers without any ad-
ditional cleaning media like steam, air or water.

The impact systems can be designed to work mecha- nically or pneumatically. In our experience, pneumatic single rapper is the best solution. The individually adjus- table impact energy permits target optimisation of the heating surface cleaning procedure to ensure the overall efficiency of the evaporators, superheaters and econo- misers are kept consistently high. This lays the basis for extending the plant‘s availability. BUS-connection in the control centre makes it possible to provide cleaning of each heating area which is both variable and process- dependent. The breakdown of a rapping device has litt- le effect on boiler operation. The single rappers can be assembled easily.

On request, we also offer rapping carriages.

Operation

By rapping the fouled convection heating surfaces the bank tubes are caused to vibrate so that the deposited combustion residues fall off.

Cleaning takes place by means of mechanical hammers or by pneumatically driven impact cylinders. We recom- mend pneumatic single rappers as their impact energy can be adjusted to the plant conditions.


SMART Clean for Boiler Diagnostics

/Analysis and Optimisation


Due to  the  multitude  of influencing  factors  and  their interdependencies,  there   cannot   be   a  global,   once defined and always applicable cleaning strategy. SMART Clean holds the intelligence to recognise  where  exactly in the boiler are the deposits,  to what  extent  and what effects  will they have on the  efficiency and  availability of the boiler.

Here,  the   combined   application   of  diagnostics   and analysis  is  the  enabler.   The  diagnostics   comes  from various sensor systems, which continuously  and directly measure   important  process  parameters.  This data   is passed on to the analysis centre where various software modules   evaluate   and  interpret   the  data.   Once  the analysis is complete,  the  results  are  transformed into necessary   cleaning   actions   incorporating   following three key information:

WHERE in the boiler is the deposit located? HOW intensive has the cleaning to be?

WHEN is the best point in time to initiate cleaning?

By selecting  the  impending  cleaning  actions,  the preservation  of boiler efficiency and  availability as well as other  factors  relevant to the  process  are taking into account.

As this is a closed loop system, the  sensors also report back how successful the cleaning has been.

Your Benefits:

  • With SMART Clean, on-load boiler cleaning only takes place when necessary
  • Less use of cleaning media
  • Less erosion on the heating  surfaces
  • Improved heat transfer and process efficiency
  • Reduced furnace exit gas temperature
  • Stable flue gas temperature at full load operation
  • More flexibility while firing fuel mixes
  • Avoidance of uncontrollable deposit formation  and reduced  shutdowns and damage