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Tube leaks in boiler components present significant challenges for power generators worldwide, resulting in extended outages, substantial revenue losses, and safety risks. Emerging technologies such as physics-based boiler modelling and Artificial Intelligence (AI) offer potential solutions, with automated monitoring solutions able to detect anomalies and predict failures 35-45% before manual inspectors, while reducing unplanned downtime and maintenance costs. Virtual Boiler Models use Computational Fluid Dynamics (CFD) to accurately map fluid flow velocities, temperatures, and thermal stress gradients across boiler components, allowing engineers to simulate scenarios that are impossible to recreate physically.
