Steam Boiler Tube Leak Detection by Acoustic Monitoring Instruments

Acoustic monitoring Instruments for Boiler tube leakage detection in Thermal Power Plants are cost effective hence must be installed immediately.
Acoustic Instruments may be used to detect early boiler tube leak to avoid secondary damage to pressure parts.Boiler acoustic tube leak detection system must be used as it prevent damage to costly boiler parts and it is very much cost effective.An increase in boiler availability of just one day will more than cover the cost of a leak detection system.




Traditional leak detection system such hearing hissing sound by ear or monitoring feed water flow or furnace vaccum is not much reliable because it can not detect small leak so damage to vital costly equipment of boiler may not be avoided.Writer noticed many instances where thermal power plants boiler allowed to run for long time due to confusion which caused permanent damage to many boiler tubes,refractory and boiler structures.Hence importance of acoustic monitoring leak detection systems sincerely felt .




Acoustic leak detection sensors detect high frequency emmissions from site of leak and Sensitive piezoelectric sensors mounted to the structure transform these acoustic waves to electronic voltage signals, which are amplified, filtered, and processed to determine energy content.




Early detection by acoustic monitoring instruments results in substantial reduction of repair times and costs with a consequent increase in plant availability and profits. The early detection of a bolier tube leak will give financial savings which will easily exceed the initial capital cost of the detection system even at the very first event.




Finally,Acoustic monitoring instruments must be intalled in boilers of thermal power plants.for more details go to


http://www.acousticmonitoring.com/


Acousti monitoring international


p(330)305-1422f(330)494-9822-16707 harbour drive n.w cantou ohio 447


http://www.proconeng.com/mainfiles/boilerleak.html


procon engineering


http://www.triple5industries.com/


http://www.steamleak.com/


know more about boiler tube leakage,avoid clinker formation and furnace explosion


http://boilerdetails.blogspot.com/

Steam Boiler Tube Leak Detection by Acoustic Monitoring Instruments

Acoustic monitoring Instruments for Boiler tube leakage detection in Thermal Power Plants are cost effective hence must be installed immediately.
Acoustic Instruments may be used to detect early boiler tube leak to avoid secondary damage to pressure parts.Boiler acoustic tube leak detection system must be used as it prevent damage to costly boiler parts and it is very much cost effective.An increase in boiler availability of just one day will more than cover the cost of a leak detection system.




Traditional leak detection system such hearing hissing sound by ear or monitoring feed water flow or furnace vaccum is not much reliable because it can not detect small leak so damage to vital costly equipment of boiler may not be avoided.Writer noticed many instances where thermal power plants boiler allowed to run for long time due to confusion which caused permanent damage to many boiler tubes,refractory and boiler structures.Hence importance of acoustic monitoring leak detection systems sincerely felt .




Acoustic leak detection sensors detect high frequency emmissions from site of leak and Sensitive piezoelectric sensors mounted to the structure transform these acoustic waves to electronic voltage signals, which are amplified, filtered, and processed to determine energy content.




Early detection by acoustic monitoring instruments results in substantial reduction of repair times and costs with a consequent increase in plant availability and profits. The early detection of a bolier tube leak will give financial savings which will easily exceed the initial capital cost of the detection system even at the very first event.




Finally,Acoustic monitoring instruments must be intalled in boilers of thermal power plants.for more details go to


http://www.acousticmonitoring.com/


Acousti monitoring international


p(330)305-1422f(330)494-9822-16707 harbour drive n.w cantou ohio 447


http://www.proconeng.com/mainfiles/boilerleak.html


procon engineering


http://www.triple5industries.com/


http://www.steamleak.com/


know more about boiler tube leakage,avoid clinker formation and furnace explosion


http://boilerdetails.blogspot.com/

Cause of clinker formation low GCV,Overfiring,Ash fusion,Mineral contentl,Primary secondary air ratio not proper,outage of soot blower clinker Grinder

Clinker Formation is due to Low GCV of coal,Mineral Content in coal,overfiring,ash fusion but accumulation in Water Wall may be Checked by Poking and Providing sufficient water into hopper for flushing,soot blowing,using clinker grinder and proper firing by proper primary secondary air ratio.


Cause of Clinker formation is high ash content,low GCV and high mineral content in coal but precaution is solution
In India Coal used in Power Plant is of often low quality which has high ash content and low GCV.Mineral content present in coal may increase this problem.In Water Wall ash is fused and stick on it.Presence of minerals content in coal produce very hard lumps of clinker which are very difficult to remove.Such clinkers are removed by pneumatic hammer during shutdown of unit.


To avoid clinker formation we must use good quality of coal which has less ash having high fusion temperature,more GCV and less mineral content in it.soot blowing and clinker grinder must be taken into service.Primary and secondary air ratio must be proper.Overfiring must be avoided.sufficient water must be used to flush slag from boiler hopper.Poking must be continous so that accumulation may be avoided.


If the quality of coal is low then it is not possible to stop clinker formation but we can stop its accumulation in furnace to some extent by proper poking at ash hoppers and providing sufficient amount of water which may flush out fused slag.Precaution is key which may reduce down time of unit.



We must not blame coal quality for clinker formation but our vigilant attitude may stop its accumulation in Furnace.


Always keep watch on regular poking.


Provide sufficient amount of water in hopper which may flush out fused slag.


Firing in Boiler must be proper so there may not be unburnt coal by using right proportion of primary and secondary air.



Fuel oil burners must be properly so there may not be unburnt oil in furnace.Fuel oil firing must be proper.Fuel oil must be properly atomized and steam must be properly charged into oil gun.



Above precaution may avoid chances of clinker formation and its deposition which may result into higher plant load factor.


For national interest we must check fuel firing to avoid unburnt fuel.



http://clinker-formation.blogspot.com/

Thermal Power Plant familarization

Introduction and some facts about large thermal power station.

Boiler is used for steam generation.

Ball Mill or Bowl mills are used for pulverisation of coal in powder form for efficient firing in boiler.

Raw Coal Feeders are used to supply coal to ball mills in controlled quantity.

PA Fan are used to transport and preheat pulverised coal to burners.

ID Fan are used to exhaust flue gases to chimeny and create vaccum in Furnace.

Electrostatic Precipitators are used to separate ash particles from flue gases to control pollution.Here collecting electrode,emmiting electrode and rapping mechanism used.

FD Fan used to provide air to boiler for help in firing.

Steam produced in boiler is further superheated in Superheaters.There are lot superheaters such as platen,pendent,convection and final superheaters.

Boiler drum used for separation of staem from water.

Boiler circulation pump used for forced circulation of water in water wall because at high pressure natural circulation is not possible.

Ash slurry pumps are used to flush ash with water.

Boiler Feed Pump used to provide water to boiler.

Deaerator used to separate dissolved air from water.

In Turbine heat energy of steam is converted into mechanical energy.

ESV which is called emergency stop valve used to stop supply of steam to turbine when unit trips.

Barring gear or shaft turning gear is used to ratate turbinr rotor at 3.15 rpm when turbine is not running to check bending of rotor due to its own weight.

LP Heaters and HP Heaters are used to heat condensate and feed water supplied to boiler to increase efficiency by steam bled from turbine extraction.

Economiser are used to heat feed water by flue gages to increase efficiency. Heat of waste flue gas is utilised here.

Air Heaters uses heat of waste flue gases to preheat primary and secondary air.There are two types of air heaters tubular and rotary.

Condenser used to condence steam exhausted from turbine.

Condensate Pump are used to supply water to Deaerator from condensers.

CW Pump used to cool steam in condensers.

Turbogenerator converts mechanical energy into electrical energy.

H2 Gas used in generators used for cooling of generators.

Seal Oil system used to seal hydrogen gas from escape from generator.


Stator Water Cooling system provides demineralised water into hollow stator conductor of generator for its cooling.

Generating Tansformer steps up volatage for transmission.

Water Treatment Plant is used to produce demineralised water for steam generation. Cation anion and degassifier tower used to separate mineral and gases from water.PAC or alum used to separate mud and silica from water.

Coal Handling Plant supplies Coal to Boiler.Merry go round system or wagon trippler used to unload coal into hoppers. Coal is crused in crusher to crush it in 25mm size.Magnetic separators used to separate metalic particles from coal.

ABCB,SF6,OCB,MOCB and VCB are circuit breakers used to make or break electricity contact at load.

Isolators are used to make or break contact at no loads.

ABT is availability based tarrif system to maintain grid discipline.

Purging is done to clean furnace from combustible gases by running IDF and FDF at atleast 30% load for 5 minutes.

Furnace explosion may be checked by timely purging and adjusting firing properly using right quantity primary and secondary air and timely oil support.

Flame scanners used to sence flame in boiler.

FSS is furnace safeguards supervisory system to safeguard boiler.

Clinker formation which caused by more ash content and mineral in poor quality coal may be checked by proper poking and using more water for flushing and use of clinker grinder.

Acoustic Instruments used to detect early boilker tube leakage to avoid secondary damage to pressure parts.






Thermal Power Plant Boiler Turbine Turbogenerator ESP
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Detect Boiler Tube Leakage by Acoustic Instrument early to avoid secondary damage to pressure parts

There must be constant vigil on possibility of Boiler Tube Leakage because small negligence may result into heavy leakage to pressure parts of Boiler,its refractories and even to its Structure Beams etc.We must constatly watch furnace vaccum which must be maintained -10 to -20 mmwl.If furnace vaccum is disturbed then we must physically inspect boiler for hissing sound of leakage of steam.Nowadays some Acoustic Instruments also available which may detect steam leakage from boiler tube.Feed water flow is another parameter which must be watched carefully to judge boiler tube leakage.Any increase of feed water flow and decreasing of deaerator level must be seriously examined.



There are several type of boiler tube leakage such as Super Heater Leakage,Water Wall Leakage and Economiser Tube Leakage,all type of boiler tube leakage are seriously dangerous for Boiler.In some cases I have seen that Economiser leakage not taken seriously and unit allowed to run for some time which resulted into chocking of Air Heater Tube which resulted into pressurisation on Boiler Furnace.


http://boilerdetails.blogspot.com/

Avoid Clinker Formation by poking,soot blowing,flushing,clinker grinder,using primary secondary air ratio and avoid overfiring

Clinker Formation in Boiler of Thermal Power Station is due to high Ash Content and Minerals present in it.Due to poor Quality of Coal ash got fused and mineral content stick into Water Wall which is very difficult to remove often requires removal by pneumatic machines.This Clinker formation may be stopped to some extent if sufficient water is sprayed into hopper and regular poking and using good quality of coal.



Accumulation of clinker may be checked if poking of hoppers done regularly and any negligence may start process of clinker deposition.If clinker is not removed immediately then same may choke hopper and often workers got burnt due to sudden fall of hot water which accumulated in hopper.


Once clinker formed into hopper than outage of unit is evident otherwise clinker may deposit in huge quantity which will be very difficult to remove because minerals content present in coal fused in ash deposit into water wall is very hard.Such hard Lumps of Clinkers requires pneumatic hammering which takes very much time.



Although cause of clinker formation is poor coal quality and high mineral content in coal but accumulation in Water Wall is result of negligence by Workers and Engineers who do not poke hopper regularly and spray insufficient amount of water into hopper which may not flush fused slag to channels.Outage of clinker grinder is also matter of concern.



Hence it is advised never blame to low coal quality,low GCV and high mineral content in coal.Instead of blaming to above factors try regular poking and provide sufficient water in hopper.Clinker Grinders must be made operational.In India coal supplied to power plants is often of low quality which has high ash content so precaution is best solution here.