Control of Acoustic Energy Input for Cleaning of Industrial Boilers

A non-intrusive cleaning method for boiler tubes at Sasol Synfuels power station at Secunda, in the Mpumalanga province of South Africa, is preferred over conventional methods that require boiler shutdown. The elected non-intrusive cleaning method utilizes sound energy waves, produced by an acoustic horn. Due to the nature of sound propagation and the effectiveness required, there is a requisite to control and operate the sonic horn. If the acoustic horn’s sound frequency is too low, it will produce higher sound energy waves that will resonate with the plant’s harmonious frequency and cause structural damage. Conversely, if the sonic horn’s sound frequency is too high, excessive noise levels may be reached and annoy plant personnel. To prevent these undesirable outcomes posed by adopting acoustic cleaning, there needs to be a regulatory system incorporated into the configuration to mitigate vibrations and limit noise. The regulatory system comprises a control system that drives the acoustic horn’s sound frequency as intended through a set point. The designed control system meets the anticipated requirements, such that it has an ideal transient response of 0.562 s, a steady-state error achieved in 1.05 s, with 0.201% overshoot, and most importantly the closed-loop system is stable.