Power plants and industrial facilities depend on heat recovery steam generator (HRSG) cleaning services to ensure their combined cycle gas turbines work efficiently, help them save money and mitigate risks. Clean systems are also crucial as regulatory pressure mounts, the demand for low-emission operations increases, and the sector adopts new digital monitoring and predictive maintenance technologies.
For this reason, it is critical to partner with the best HRSG cleaning services for optimal plant output and fuel efficiency. Proactive cleaning helps minimize downtime and extends equipment lifespan.
The Hidden Costs of a Dirty HRSG
A dirty HRSG can significantly hurt your bottom line. Fouling and debris accumulation, in particular, erode thermal performance and cause the equipment to burn more fuel.
Because facilities must shut HRSG equipment down to address fouling, the unforeseen cleaning and maintenance costs exceed $4.4 billion annually across major industries. Fouling results in losses of 0.25% to 30% in gross domestic product. It could also cause 1% to 2.5% of global carbon dioxide (CO2) emissions and a 20% increase in fossil fuel costs.
Likewise, deposit buildup often causes significant backpressure that requires expensive repairs. You also risk shortening the life of your HRSG equipment and increasing the risk of regulatory noncompliance and cumulative costs.
What Sets the Best HRSG Cleaning Services Apart?
The best HRSG cleaning service deploys various approaches, such as robotics systems and blasting, to produce exceptional results. These technological innovations and methodologies aim to minimize disruptions so plants can maintain peak performance.
| Dry ice blasting | Uses dry ice pellets to blast high pressure at HRSG equipment and remove debris |
| Robotic cleaning | Utilizes automated robotics with remote-control capabilities to clean hard-to-reach areas |
| Remote monitoring | Allows facility managers to detect malfunctions and schedule repairs accordingly through sensors and cameras that enable real-time quality control |
| Hydroblasting | Shoots pressurized water at surfaces to remove dirt and other material buildup |
| Grit blasting | Blows glass, aluminum oxide, plastic and other abrasive materials in a pressurized stream |
| Pressure wave impulse | Ignites a combustible gas near the HRSG tubes to dislodge debris from surfaces |
| Chemical cleaning | Applies chemical solutions to remove grease and oil |
Some methods are safer for people and the environment than others. For instance, disposing of contaminants after chemical cleaning may be more challenging than after robotic cleaning or ice blasting. Specific methods also require more downtime. In the end, facilities must prioritize safety and speed above all else.
Top 3 HRSG Cleaning Services for Your Business
When your facility equipment is dirty, you want to work with the best HRSG cleaning services. The following three businesses employ cutting-edge technologies and adhere to safety best practices for optimal results.
1.   Environmental Alternatives Inc.
Environmental Alternatives Inc. (EAI) uses ice blasting to clean HRSG equipment in various sectors. It can sanitize food service equipment, remove corrosion from vehicles, or eliminate residue and refractory coatings from castings in foundries.
EAI was the first company to introduce CO2 ice pellets to clean industrial plants. The method is nondestructive, environmentally friendly and safer to handle.
Key features:
- Applies ice blasting and CO2 blasting to dislodge unwanted debris
- Less abrasive than other media, and does not generate waste
- Vaporizes upon contact with equipment to avoid harming employees
2.   Precision Iceblast Corp.
Precision Iceblast Corp. deploys patented technology for HRSG tube cleaning, which entails ice blasting. The high-pressure system shoots air that is 200 times greater than CO2. PIC has leaned into this approach extensively, cleaning 1,500 HRSG units worldwide.
Some of the fouling residue that PIC can remove includes ammonia, sulfur, iron oxide and insulation. This increases power outputs and ensures higher thermal efficiency and steam production.
Key features:
- Uses its HRSG Deep Cleaning patented technology
- Successfully cleaned over 1,500 units
- Improves power plant efficiency and performance
3.   GE Vernova
GE Vernova uses PressureWave+ technology, which creates pressurized waves to penetrate and eliminate debris deep in the HRSG tubes. The method does not damage the tubing and does not take long to complete.
This business has completed over 200 PressureWave+ cleanings in five years with excellent results and no safety concerns. It does not require scaffolding, and experts can ignite it remotely.
Key features:
- Relies on PressureWave+ technology
- Has cleaned over 200 units in five years
- Enhances safety with zero scaffolding and remote combustion
How to Choose the Right HRSG Cleaning Company
Always select an HRSG cleaning company with a proven track record of industry experience. This should include taking maximum safety precautions and achieving positive system performance outcomes.
Compare their methods and cleaning technologies, and how much downtime each technique requires. Companies must also have extensive knowledge of compliance standards to avoid expensive violations.
HRSG cleaning companies should be able to tailor their solutions to your facility’s needs and set strong performance metrics to demonstrate long-term benefits and financial gains.
Future-Proofing Your HRSG Unit With Proper Cleaning
You must clean your HRSG unit for it to function at maximum capacity. Essentially, business success hinges on it. Future-proof your facility equipment by partnering with the best HRSG cleaning services.
