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SMART Clean for Pulp & Paper

Clyde Bergemann’s SMART Clean system is a superior way to intelligently manage your sootblower operations and increase the heat transfer in your heat exchangers.
Traditional sootblowing systems are based on a fixed cycle, or are at the operator’s discretion, to initiate cleaning events. Without knowing where the fouling has been occurring inside their boiler, the risk of under or over cleaning the tubes is high. This style of cleaning can result in lower heat transfer from pluggage or forced shut downs due to clinkers, both adversely affecting the thermal efficiency and plant heat rate of your boiler.

SMART Clean transforms your sootblowing system into an intelligent, closed-loop control system that uses real-time boiler data to initiate cleaning events, when needed, where needed and with the appropriate intensity. Comprised of a SMART Controls platform and Thermodynamic Modelling (TDM) feedback, the SMART Clean system is the ultimate weapon against carry over and plugging problems.

Boiler information is gathered from process data, which the software analyses through an algorithm to manage sootblower operations by calculating the cleanliness of heat exchangers in the convection pass of your boiler. The system then determines when to clean, where to clean and how intensively to clean. This results in your tubes being properly cleaned, eliminating under or over cleaning, pluggage and clinkers, while increasing the heat transfer.

Following a cleaning event, the software records the event’s impact on ash removal using calculations based on a deposit accumulation ratio and the predicted heat transfer degradation rate. The system then determines the priority for each sootblower based on the dirtiness level of each zone and selects the highest priority sootblower first for the next cleaning cycle, ensuring the heavily fouled areas are cleaned before they become problematic, with the most effective sootblower.

SMART Clean Process Summary

Clyde Bergemann’s SMART Clean process is an iterative and self-teaching process, based on the following steps:

Step 1:  Gather All Information

Boiler process and performance data is gathered from two different types of sources: indirect sources from boiler operations (steam temperatures, flue gas temperatures, etc.) and direct sources from installed sensors.

Step 2:  Interpret the Information

The quantity and the quality of incoming data can be variable. Further it requires a core understanding of the fouling processes and their effect on the variable being monitored, including the time dimension. Clyde Bergemann has developed algorithms to cut through the massive volume of data from the process and sensors to provide a cleaning solution, which permits the next step to proceed based on scientific evidence.

Step 3:  Automated Actuation

Once the analytical process from Step 2 is complete, the system activates the necessary cleaning equipment in the convection pass (retractables). The activation of the specific cleaning device ensues with prescribed cleaning intensities.  Parameters such as blowing pressure, blowing speed, and zone by zone control are precisely directed according to the local cleaning requirements. The goal being optimum cleaning intensity, frequency and location in conjunction with actual fouling location and tenacity.

Step 4:  Measurement and Judgment of Response

Having initiated and operated a particular cleaning device, the system then makes a judgment of the perceived success. This judgment will be based on the resulting data from the cleaning event. For example, for furnace cleaning, the local heat flux improvement will be compared to an acceptable clean level of heat flux for the current boiler load. The thermal impact will also be compared to the acceptable level for the tube.

The SMART Clean system will also use the existing flue gas draft differential pressures (DP) as a process variable and will calculate effectiveness for each sootblower on flue gas DP.

Variable Pressure/Flow Control Module

A variable flow/pressure module can be added as an option to allow operators the ability to adjust cleaning pressures from the controls system, rather than the poppet valve. Using this, the cleaning pressure can be varied to provide the proper intensity to clean each tube bank differently within the same lance’s path. It can also provide cleaning media savings when used in conjunction with Single Pass Cleaning by reducing cleaning media flow. (Note:  Pressure control valve must be capable of modulating from input of control system).