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Boiler tube leakage prediction through IT & digitization



Challenge Summary

The boiler tubes have to withstand the heat from the flue gas, created by burning coal and transport this to the steam generator. At any point a tube leakage can occur, severely impacting power plant operations and causing unplanned shutdowns. Annually, there are between 2 to 10 tube leaks per unit, making tube failure a common cause of loss of availability of power. To prevent secondary damages on pressure parts like water wall tubes, superheater tubes, and reheater tubes, the operating engineers constantly have to watch out for leakages. The main reason for tube leakages is overheating, defective welds, erosion, and internal corrosion. We need to develop a system that can actively monitor the boiler tubes with sensors to detect any leakage whenever it goes beyond the threshold limit.

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