Boiler Acoustic Steam Leak Detection Systems-increasing your boiler availability and profits
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
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procon engineering
http://www.triple5industries.com/
http://www.steamleak.com/
know more about boiler tube leakage,avoid clinker formation and furnace explosion
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Saturday, July 31, 2010
Wednesday, July 14, 2010
To avoid furnace explosion you must ensure that ther must not be leakage of oil into
Boiler Furnace Explosion-avoid it
To avoid furnace explosion you must ensure that ther must not be leakage of oil into boiler furnace and trip the boiler immdiately if flame disappears.Purging of boiler is necessary after every tip out.
There is one more precaution which is if at the start of ignitors or oil rows the flame is not established immediately then purge the furnace and relight again.
To avoid furnace explosion you must ensure that ther must not be leakage of oil into boiler furnace and trip the boiler immdiately if flame disappears.Purging of boiler is necessary after every tip out.
There is one more precaution which is if at the start of ignitors or oil rows the flame is not established immediately then purge the furnace and relight again.
Avoid Clinker Formation in Boiler using good quality coal,poking,soot blowing,flushing slag by sufficient water from hopper
Avoid Clinker Formation in Boiler using good quality coal,poking,soot blowing,flushing slag by sufficient water from hopper
Clinker Formation in Boiler of Thermal Power Station is due to high Ash Content which have low fusion temperature below 1500 degree centrigrade 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 deposition may be stopped to some extent if sufficient water is sprayed into hopper and regular poking to remove deposition and using good quality of coal.Ash fusion temperature must be above 1500 degree centrigrade and soot blowing regularly at load by enjecting steam by wall blowers.Overfiring is also responsible hence firing must be properly adjusted by proper balance of primary and secondary air in boiler.
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 with ash deposit into water wall.Such hard Lumps of Clinkers requires pneumatic hammering which takes very much time resulting in forced closure of unit for weeks.
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 and soot blower is also matter of concern may be termed as negligence.
Hence it is advised never blame to low coal quality,low GCV,low ash fusion temperature 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.Soot blowing must be done regulaly by injecting steam.In India coal supplied to power plants is mostly of low quality which has high ash content so precaution is best solution here to avoid deposition and formation of clinkers in Boiler.
Precaution may stop clinker deposition and formation so remain vigilant.
Clinker Formation in Boiler of Thermal Power Station is due to high Ash Content which have low fusion temperature below 1500 degree centrigrade 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 deposition may be stopped to some extent if sufficient water is sprayed into hopper and regular poking to remove deposition and using good quality of coal.Ash fusion temperature must be above 1500 degree centrigrade and soot blowing regularly at load by enjecting steam by wall blowers.Overfiring is also responsible hence firing must be properly adjusted by proper balance of primary and secondary air in boiler.
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 with ash deposit into water wall.Such hard Lumps of Clinkers requires pneumatic hammering which takes very much time resulting in forced closure of unit for weeks.
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 and soot blower is also matter of concern may be termed as negligence.
Hence it is advised never blame to low coal quality,low GCV,low ash fusion temperature 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.Soot blowing must be done regulaly by injecting steam.In India coal supplied to power plants is mostly of low quality which has high ash content so precaution is best solution here to avoid deposition and formation of clinkers in Boiler.
Precaution may stop clinker deposition and formation so remain vigilant.
Sunday, July 11, 2010
Boiler Tube Leakage detect eaely by Acoustic Instrument to avoid secondary to pressure parts of boiler
Superheater WaterWall Economiser Tube Leakage detection by Acoustic Instruments to avoid secondary damage.BTL may damage boiler tubes refractory structure beams
and choke Airheater tubes so it must be watched carefully
Detect Boiler Tube Leakage Early to avoid secondary Damage
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,Wter 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.
and choke Airheater tubes so it must be watched carefully
Detect Boiler Tube Leakage Early to avoid secondary Damage
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,Wter 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.
Causes of Clinker Formation and how to avoid its accumulation ?
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.
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.
Boiler Turbine Turbogenerator ID FD PA Fan BFP LPH HPH Deaerator GT Air heaters Economisers EP ABT FSS Scanners
Boiler Turbogenerator GT ESP ABT FSS Deaerator Scanners Soot blowers Air heaters Economisers Superheaters Reheaters ID FD PA Fan BFP LPH HPH CW Pump
Introduction and some facts about large thermal power station for efficient operation.
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 and storage.Nowadays Drum less once through boiler also used which operates at super critical temerature and Pressure.
Boiler circulation pump used for forced circulation of water in water wall because at high pressure natural circulation is not possible.
Soot Blowers used to remove soot from water wall,Superheater,Reheaters and Air Heaters by injecting steam into heating surfaces.
Ash slurry pumps are used to flush ash with water.
Boiler Feed Pump used to provide water to boiler Drum.
Deaerator used to separate dissolved air from Feed 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.
Reheaters used to reheat steam exhausted from HP turbine.After reheating upto 535 degree centrigade same steam is utilised in Intermediate Pressure Turbine.
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 condenser Hot well.
CW Pump used to cool steam exhausted from turbine into condensers.
Raw Water is Circulated by cw pump into condenser tube hence leakage from condenser tubes must be checked to avoid mixing of raw water into Hot well.
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.Here minerals removed from water and ph value is maintained near 7 and silica value must less tham 0.02 ppm
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 ID Fan and FD Fan at atleast 30% load for 5 minutes to avoid furnace explosion.
Furnace explosion may be checked by timely purging and adjusting firing properly using right quantity primary and secondary air and timely oil support and avoiding leakage of fuel oil in boiler.Furnace must be purged properly again if flame is not established during lightup of boiler.
Flame scanners used to sense flame in boiler to detect flame failure to avoid boiler furnace explosion.
FSSS is furnace safeguards supervisory system to safeguard boiler.
Clinker formation which caused by more ash content having low fusion temperature and mineral in poor quality coal may be checked by proper poking and using more water for flushing and use of clinker grinder and regular soot blowing.Overfiring which is also cause of clinker formation may be avoided by proper primary and secondary air ratio.
Acoustic Instruments used to detect early boiler tube leakage to avoid secondary damage to pressure parts,Refractory and structures of Boiler.Boiler must be immediately shut down in case of Boiler tube Leakage.
http://tpp-4u.blogspot.com/
Introduction and some facts about large thermal power station for efficient operation.
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 and storage.Nowadays Drum less once through boiler also used which operates at super critical temerature and Pressure.
Boiler circulation pump used for forced circulation of water in water wall because at high pressure natural circulation is not possible.
Soot Blowers used to remove soot from water wall,Superheater,Reheaters and Air Heaters by injecting steam into heating surfaces.
Ash slurry pumps are used to flush ash with water.
Boiler Feed Pump used to provide water to boiler Drum.
Deaerator used to separate dissolved air from Feed 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.
Reheaters used to reheat steam exhausted from HP turbine.After reheating upto 535 degree centrigade same steam is utilised in Intermediate Pressure Turbine.
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 condenser Hot well.
CW Pump used to cool steam exhausted from turbine into condensers.
Raw Water is Circulated by cw pump into condenser tube hence leakage from condenser tubes must be checked to avoid mixing of raw water into Hot well.
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.Here minerals removed from water and ph value is maintained near 7 and silica value must less tham 0.02 ppm
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 ID Fan and FD Fan at atleast 30% load for 5 minutes to avoid furnace explosion.
Furnace explosion may be checked by timely purging and adjusting firing properly using right quantity primary and secondary air and timely oil support and avoiding leakage of fuel oil in boiler.Furnace must be purged properly again if flame is not established during lightup of boiler.
Flame scanners used to sense flame in boiler to detect flame failure to avoid boiler furnace explosion.
FSSS is furnace safeguards supervisory system to safeguard boiler.
Clinker formation which caused by more ash content having low fusion temperature and mineral in poor quality coal may be checked by proper poking and using more water for flushing and use of clinker grinder and regular soot blowing.Overfiring which is also cause of clinker formation may be avoided by proper primary and secondary air ratio.
Acoustic Instruments used to detect early boiler tube leakage to avoid secondary damage to pressure parts,Refractory and structures of Boiler.Boiler must be immediately shut down in case of Boiler tube Leakage.
http://tpp-4u.blogspot.com/
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