The diaphragm-type sonic soot blower broke but was not detected in time. Only after the boiler was shut down did it become apparent that the accumulated dust had "blocked" the flue.The diaphragm is the core sound-producing component of the acoustic blower. Under the pressure of high-pressure gas, it vibrates hundreds of times per second and is a high-frequency fatigue part. Once the diaphragm breaks, the blower stops producing sound, but the DCS system often only shows "Blower operating status is normal" - because gas is still being expelled from the broken area, creating the illusion that "blowing is still in progress". The operator relies on the automatic blowing program and is unaware that the blower has already failed.When the boiler was shut down for inspection, it was discovered that the inner wall of the flue had accumulated ash to a thickness of 50 to 80 mm. The ash had clogged the heat exchanger tubes, resulting in a significant decline in heat transfer efficiency - the exhaust temperature of the boiler increased by 15 to 20 degrees Celsius, and the thermal efficiency decreased by 1.5% to 2%. The annual fuel cost loss could reach **100,000 to 300,000 yuan**. What's worse, the sulfate in the ash corroded the tube walls, accelerating the aging of the heat exchanger tubes.【Our Solution】Ensuring that the soot blowing operation is "always present" from two aspects: long service life of the diaphragm and immediate alarm in case of failure:The material of the diaphragm has been upgraded to imported titanium alloy (Ti-6Al-4V), with a fatigue life of ≥ 100 million vibrations (calculated based on 300 vibrations per minute, 8 hours of operation per day, it is equivalent to continuous operation for 2.3 years). Additionally, a dual diaphragm design is provided: when the main diaphragm breaks, the backup diaphragm automatically takes over and the soot blowing does not stop. During replacement, both diaphragms are replaced together, doubling the lifespan.② Each dust blowing device is equipped with a sound pressure sensor (feedback monitoring function), which can monitor the sound wave frequency and sound pressure level in real time. When the diaphragm breaks and the sound pressure level drops by more than the set threshold (normal ≥ 120 dB, after breakage it drops to < 100 dB), the system will automatically trigger an alarm and send a text message to the maintenance personnel. On the DCS screen, a prominent prompt "XX dust blowing device has abnormal sound pressure" will be displayed, eliminating the blind area of "mistakenly believing it to be normal".③ Provide membrane pre-diagnosis service: By analyzing the historical sound pressure data trends, we can predict the remaining lifespan of the membrane in advance. Diaphragm-type sonic soot blower We will proactively arrange for replacement before the membrane breaks, thus avoiding sudden failures.Final effect: The effective operation rate of the blower is ≥ 99%, the ash accumulation thickness in the flue is controlled within ≤ 15mm, the flue gas temperature is reduced by 10 to 15℃ compared to the state without blowing ash, the boiler thermal efficiency is increased by 1.5% to 2.0%, and the annual fuel cost savings amount to several million yuan.