Early tube leak detection system for steam boiler at KEV power plant

Due to growing electricity demand, developing an efficient fault-detection system in thermal power plants (TPPs) has become a demanding issue. The most probable reason for failure in TPPs is equipment (boiler and turbine) fault. Advance detection of equipment fault can help secure maintenance shutdowns and enhance the capacity utilization rates of the equipment. Recently, an intelligent fault diagnosis based on multivariate algorithms has been introduced in TPPs. In TPPs, a huge number of sensors are used for process maintenance. However, not all of these sensors are sensitive to fault detection. The previous studies just relied on the experts’ provided data for equipment fault detection in TPPs. However, the performance of multivariate algorithms for fault detection is heavily dependent on the number of input sensors. The redundant and irrelevant sensors may reduce the performance of these algorithms, thus creating a need to determine the optimal sensor arrangement for efficient fault detection in TPPs. Therefore, this study proposes a novel machine-learning-based optimal sensor selection approach to analyze the boiler and turbine faults. Finally, real-world power plant equipment fault scenarios (boiler water wall tube leakage and turbine electric motor failure) are employed to verify the performance of the proposed model. The computational results indicate that the proposed approach enhanced the computational efficiency of machine-learning models by reducing the number of sensors up to 44% in the water wall tube leakage case scenario and 55% in the turbine motor fault case scenario. Further, the machine-learning performance is improved up to 97.6% and 92.6% in the water wall tube leakage and turbine motor fault case scenarios, respectively.

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Improved Early Detection of Tube Leaks Faults in Pulverised Coal-fired Boiler Using Deep Feed Forward Neural Network

Abdul Karim,

Mohd Mustafah,

Zainal Abidin

2024

JST

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Boiler tube leaks significantly reduce the operational availability of power units, yet their early detection and prediction have not been fully realised in the industry. This paper introduces a novel approach employing deep feedforward neural networks for early detection of boiler tube leaks in pulverised coal-fired boilers. Early detection enhances repair planning, minimising downtime and production losses. It also improves monitoring and control of boiler tube failures, thereby optimising power plant operations and revenue. Diverse deep neural network models were developed and rigorously tested by leveraging 9 years of operational data (2012–2020). Exhaustive hyper-parameter optimisation, involving seven parameters, substantially improved predictive accuracy. By achieving training and testing accuracies of 82.8% to 99.3%, the study assessed their ability to detect boiler tube leaks over the same 9-year span, providing insights into leak detection capabilities. The models notably predicted all 12 identified tube leak events, averaging a 14-day lead time before boiler shutdown. In addition to leak prediction, a leak detection matrix was devised to analyse residual behaviour and reduce the likelihood of false alarms. However, the models’ predictive performance was observed to be limited to the following year, with satisfactory results for 2021 only. Incorporating the 2021 data into retraining significantly improved the predictions for 2022. The study concludes that while the models demonstrate robust short-term prediction capabilities, they require continuous retraining to maintain accuracy and relevance. This ongoing refinement is essential for keeping the models up-to-date and reliable in predicting future boiler tube leaks.

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Early tube leak detection system for steam boiler at KEV power plant

Cited by 3 publications

References 6 publications

Evaluating the effectiveness of a boiler plant’s predictive maintenance system

Evaluating the effectiveness of a boiler plant’s predictive maintenance system

Real-World Data-Driven Machine-Learning-Based Optimal Sensor Selection Approach for Equipment Fault Detection in a Thermal Power Plant

Improved Early Detection of Tube Leaks Faults in Pulverised Coal-fired Boiler Using Deep Feed Forward Neural Network

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