Enhancing boiler efficiency with a damper drive retrofit

A major gas processing facility in the Middle East was experiencing declining performance in two utility boilers. The original actuator systems on the forced draft (FD) fan dampers had reached obsolescence, and with spare parts no longer available, operators were forced to run the dampers manually. Over time, this impacted efficiency, reduced control accuracy and increased operational risk. Challenges like this are common in mature plants across the region, where aging equipment continues to limit reliability and stable operation.

When aging equipment becomes a risk to stability

Manual operation was never intended to replace automated damper control. Inconsistent airflow made it harder to maintain steady combustion, increased operator workload, and created additional risk during process disturbances. The customer needed a modern, engineered replacement that would restore automation and provide long-term reliability - not just a like-for-like component change.

A complete retrofit built around Neles Easyflow™

Valmet proposed a fully engineered retrofit using the Neles Easyflow damper drive control panel, designed specifically for combustion airflow control. Instead of supplying just one component, Valmet provides all mechanical, pneumatic, and control elements as a complete, engineered package tailored to the customer’s application. The retrofit included a damper drive control panel with pneumatic cylinder, mechanical linkages and junction boxes, smart positioners and accessories, and application-specific engineering and design support. The project also demonstrated how the Neles Easyflow solution adapts well to regional operating conditions, strengthening Valmet’s reference base in the Middle East.

Immediate improvements in operation and efficiency

Once commissioned, the new damper drive system restored accurate and consistent airflow control. The boilers were returned to automatic operation, reducing manual intervention while improving efficiency and safety. The customer gained smooth and reliable damper movement, automated boiler operation with reduced operator workload, improved combustion stability and overall efficiency, and a proven upgrade concept applicable to other units in the plant. What began as a reliability issue became an opportunity to strengthen performance across the site.

Why Valmet was selected

The customer highlighted three reasons for choosing Valmet as their partner: a requirement for a complete, engineered replacement for obsolete actuators, strong application expertise and close collaboration, and proven performance supported by global references.

Extending the life and value of existing boiler assets

With the Neles Easyflow damper drive solution in place, the facility regained reliable, precise boiler control and reduced operational risks. The retrofit extended the useful life of key assets while improving day-to-day stability - a clear example of how engineered pneumatic solutions can support long-term performance in mature industrial plants.