In the thermal power station, the coal fired boiler are made up of thousands of boiler tubes. It carries the high pressure steam running across the boiler. Boiler tubes are subjected to prolong exposure at elevated temperature will lose their load bearing capacity.

Prevent unplanned shutdown from the boiler tube leakage

Some common boiler leakage driving factors:

• In the PC boiler, the excessive high FEGT operation cause the boiler tube of early thermal degradation.
• In the CFB boiler, the high abrasion of circulating sands and volatile turbulence flow, will eventually lead to the boiler tube leakage situation.

TUBE LEAKS ARE COSTLY AND DANGEROUS,
IT CAN LEAD TO UNEXPECTED DOWNTIME AND EXTENSIVE DAMAGE
IF IT WERE UNDETECTED FOR LONG PERIODS OF TIME

Boiler Tube leakage Early Detection System

Boiler Tube Leakage Detection (BTLD)  system detects the leak and provide warning to the plant operators, to prevent unplanned shutdown to the operation.

Principle of Operation:

Using the principle of acoustic sound monitoring with Enhanced Acoustic Sensor, sound signal will be collected from all boiler (water wall, superheated, reheat and economizer tubes) and converted into analog signals. The Acoustic Monitoring and Detection System will collect and analyse the acoustic data to monitor and identify the leakage condition across the boiler in real time.

The monitoring system uses Fast Fourier Transform (FFT) Technology to convert the sound signal into frequency spectrum and display in the form of bar chart. The analysis is based on the continuous intensity of the sound at a particular frequency to tell whether it is a tube leak.

The Acoustic Monitoring and Detection System will collect and analyse the acoustic data to monitor and identify the leakage condition across the boiler in real time.

Key Features :

• EARLY LEAKAGE DETECTION & IDENTIFY THE LOCATION – High sensitivity and complete coverage for the whole boiler, the detection and alarm system can detect the small leak up to 1mm and identify the location of leakage.
• ADVANCED ANALYSIS & SOUND SPECTRUM – to identify and track the tube leak conditions
• USER-FRIENDLY INTERFACE – precise location identification, live listening, auto soot purging, and alarm notification feature.
• INTERFACE WITH DCS AND REMOTE MONITORING – communicate with plant DCS or SCADA via Modbus communication.
• SELF-DIAGNOSTIC – to check if individual channel is healthy.

Benefits:

• Early detection of boiler tube leakage will minimise the boiler damage
• Advanced notice of leak problems to minimize costs of damage and repair
• Controllable downtimes for repairs to lower operation replacement costs (Planned shutdown for repair)