Client Success Story

Zealogics HMS Optimizes Power Generation by Predicting Heat Exchanger Fouling in a Combined Cycle Power Plant



Unforeseen heat exchanger fouling in combined cycle power plant operations significantly impacts efficiency and overall power generation. Traditional methods for monitoring fouling, such as U coefficient testing, are often:


Client Challenge

Client wanted Zealogics to develop a Web App, Web API, multiple request services & Desktop App for Health Monitoring of ICRC. These remote infra. are not accessible via the internet but through restricted client authorized engineers. Developing the application with old hardware setup, low performance and connecting remotely via VPN over VPN was a challenge.


Traditional methods of heat exchanger monitoring pose several challenges:

  1. Intermittent: They offer only snapshots, potentially missing critical fouling stages.
  2. Labor-Intensive: Manual testing requires plant shutdowns and dedicated personnel, increasing costs.
  3. Reactive: Detection often occurs after fouling has caused efficiency losses. These limitations lead to:
  • Reduced Power Output
  • Increased Fuel Consumption
  • Unplanned Outages
  • Higher Maintenance Costs

Ideal Solution Proposed

The Zealogics team developed a powerful Health Monitoring System (HMS) built on the robust foundation of Angular and .NET frameworks, utilizing MariaDB for data storage. This innovative system empowers power plant operators with a proactive approach to heat exchanger management.


HMS offers a comprehensive suite of features, including:

  1. Real-Time Data Acquisition: Collects and analyzes data from heat exchanger sensors for comprehensive health monitoring.
  2. AI-Powered Fouling Prediction: Sophisticated algorithms predict fouling events before performance is affected.
  3. Advanced Alerts: Customizable alerts for critical parameters like CPU temperature, power surge, and fan speed.
  4. Flexible Data Exploration: Search by rack type, subsystem, or alert history for in-depth analysis.
  5. Alert Management: Pause alerts and use insights for informed maintenance decisions.


Zealogics HMS delivers:

  • Maximized Power Generation: Ensures consistent power output by optimizing heat exchanger efficiency.
  • Reduced Fuel Consumption: Minimizes excess fuel burning, lowering costs and environmental impact.
  • Minimized Unplanned Outages: Prevents unexpected shutdowns through predictive maintenance.
  • Optimized Maintenance Costs: Reduces unnecessary procedures with targeted cleaning.
  • Enhanced Situational Awareness: Provides real-time data and alerts for comprehensive plant health monitoring.
  • Improved Decision-Making: Empowers proactive maintenance planning and resource allocation. A leading power plant implemented Zealogics HMS, witnessing:
  • 5% Increase in Power Output
  • 3% Reduction in Fuel Consumption
  • 80% Reduction in Unplanned Outages
  • 15% Decrease in Maintenance Costs
  • Improved Engineer Efficiency
This is a staging enviroment