Boiler Maintenance Optimization
The power plant leveraged high-fidelity data analysis to proactively identify, prioritize, and fix damaged boiler tubes to avoid forced outages.
Challenges
- Manual inspections left large portions of the boilers completely unchecked
- The plant experienced more than three forced outages each year due to asset failures
Solutions
Cantilever™:
- Data: Rapid Ultrasonic Gridding (RUG) inspection using TOKA® series robot
- Platform: Software modules presenting 2D & 3D corrosion maps and digital twin with color-coded thickness measurements, in-depth analysis, and robust reporting including repair recommendations
Results
- More than 28 million UT data readings were collected between the two boilers
- The data points populated illustrative maps, models, and digital twins in the Cantilever Platform
- The data illustrated where immediate repairs needed to be made as well as lower-priority weakened areas
- The Platform identified more than 65 boiler tubes that were ready to fail before the next planned outage
- The entire Cantilever process, from robotic inspection and data analysis to repairs being made, was completed within the plant’s five-day outage