MISTRAS | TRIPLE 5 AMS™ for HRSGAcoustic_Emission/AMS_for_HRSG.pdf · Heat Recovery Steam...
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Specificaons subject to change without noce. Copyright © 2013 MISTRAS Group, Inc. All Rights Reserved. www.mistrasgroup.com One Source for Asset Protection Solutions Products & Systems Division Application Brief #210A-12100-02 The Acousc Monitoring System is used for early tube leak detecon on pulverized coal power boilers, recovery boilers, feedwater heaters and Heat Recovery Steam Generators (HRSGs). The Triple 5 AMS-3 for early tube leak detecon has been used in convenonal power boilers very successfully over the past 25 years. Non- invasive sensors, mounted on the boiler wall, are listening for a change in the normal background noise of the boiler that indicates a tube leak. The AMS-3 provides 24-7 real me data that tracks the progression of a tube leak. The same technology, and resulng benefits, is now being applied to HRSG’s. HRSG operators report that tube leaks have been most troublesome at the Superheater and Reheater tube stub welds to the headers and Reheat drain areas. Early knowledge of these leaks provides a plant with informaon to make decisions on connued operaon of the unit and scheduling repair during a planned outage. Economic, environmental, and technological changes are reshaping the marketplace for electric power. Gas plants are being relied on to provide a significant amount of our electricity. This shiſt in the marketplace highlights the need for increased reliability and the need to avoid downme. Tradional methods for tube leak detecon, visual observaon of moisture in auxiliary equipment (Connuous Emission Monitoring System), boiler make up increases, visual steam from stack exit and audible leak noises or water dripping aſter shutdown, do not provide early warning of a leak. In addion, plant operators are not able to locate the area of the leak with tradional leak detecon methods. MISTRAS’, Triple 5 AMS™ provides an early indicaon of a leak, at least 2 weeks before tradional methods, and helps plant operators to locate the leak based on sensor locaon and signal amplitude. The MISTRAS | Triple 5 AMS™ uses sounding rods and high temperature sensors to listen for leaks. The sounding rods aach perpendicularly to the cold side of the inner liner of a HRSG. The rods do not penetrate the inner liner, instead they are fillet welded to the cold side and pass thru the insulaon and outer casing to the outside of the unit. The inner liner acts as a diaphragm that vibrates synchronously with low and high frequency sounds that transmit through the combuson gases and boiler wall/ liner. The sensor converts the vibraon to an electrical voltage for processing by an amplifier filter box. The resulng trend ulizes the air and metal-borne frequencies generated by a leak to MISTRAS | TRIPLE 5 AMS™ for HRSG FEATURES The Acousc Monitoring System includes all the hardware/soſtware for installaon on your HRSG. • 1 Data logger and process interface hardware • 4 Amplifiers • 8 Sensors • 8 Cables • 8 Waveguides to mount to inner liner • 2 NEMA and 8 protecve sensor boxes • HRSG AMS TM soſtware • Plant specific soſtware and high signal alarm outputs • 1 year of Weekly Surveillance, a remote monitoring service • Installaon, Maintenance & Operaon Manuals • MISTRAS provided operator training BENEFITS • Early indicaon of a tube leak, before tradional plant methods • Reduce secondary damage • Manage power market exposure/risk • Locate leak(s) before unit comes offline • Trend severity & progression of leak with real me data • Schedule maintenance vs. forced outage • Preplan jobs with correct assets • Scalable installaon opons Heat recovery steam generators (HRSGs) pose a unique set of operaonal challenges, due in part to their rapid startup capabilies and high operang efficiencies. Prevenng HRSG tube failures (HTFs) is a priority, but complex failure paths, which are influenced by cycle chemistry or thermal transients, are difficult to understand and migate. Limited access and other complexies make inspecon and repair of HRSGs very difficult.* Read on to discover how the MISTRAS | TRIPLE 5 AMS TM can help. A sounding rod w/ high-temperature sensor box.
Transcript of MISTRAS | TRIPLE 5 AMS™ for HRSGAcoustic_Emission/AMS_for_HRSG.pdf · Heat Recovery Steam...
Specifications subject to change without notice. Copyright © 2013 MISTRAS Group, Inc. All Rights Reserved. www.mistrasgroup.com
One Source forAsset Protection
Solutions
Products & Systems Division Application Brief
#210A-12100-02
The Acoustic Monitoring System is used for early tube leak detection on pulverized coal power boilers, recovery boilers, feedwater heaters and Heat Recovery Steam Generators (HRSGs).
The Triple 5 AMS-3 for early tube leak detection has been used in conventional power boilers very successfully over the past 25 years. Non-invasive sensors, mounted on the boiler wall, are listening for a change in the normal background noise of the boiler that indicates a tube leak. The AMS-3 provides 24-7 real time data that tracks the progression of a tube leak. The same technology, and resulting benefits, is now being applied to HRSG’s.
HRSG operators report that tube leaks have been most troublesome at the Superheater and Reheater tube stub welds to the headers and Reheat drain areas. Early knowledge of these leaks provides a plant with information to make decisions on continued operation of the unit and scheduling repair during a planned outage.
Economic, environmental, and technological changes are reshaping the marketplace for electric power. Gas plants are being relied on to provide a significant amount of our electricity. This shift in the marketplace highlights the need for increased reliability and the need to avoid downtime.
Traditional methods for tube leak detection, visual observation of moisture in auxiliary equipment (Continuous Emission Monitoring
System), boiler make up increases, visual steam from stack exit and audible leak noises or water dripping after shutdown, do not provide early warning of a leak. In addition, plant operators are not able to locate the area of the leak with traditional leak detection methods. MISTRAS’, Triple 5 AMS™ provides an early indication of a leak, at least 2 weeks before traditional methods, and helps plant operators to locate the leak based on sensor location and signal amplitude.
The MISTRAS | Triple 5 AMS™ uses sounding rods and high temperature sensors to listen for leaks. The sounding rods attach perpendicularly to the cold side of the inner liner of a HRSG. The rods do not penetrate the inner liner, instead they are fillet welded to the cold side and pass thru the insulation and outer casing to the outside of the unit. The inner liner acts as a diaphragm that vibrates synchronously with low and high frequency sounds that transmit through the combustion gases and boiler wall/liner. The sensor converts the vibration to an electrical voltage for processing by an amplifier filter box. The resulting trend utilizes the air and metal-borne frequencies generated by a leak to
MISTRAS | TRIPLE 5 AMS™ for HRSG
FEATuRESThe Acoustic Monitoring System includes all the hardware/software for installation on your HRSG.
• 1 Data logger and process interface hardware• 4 Amplifiers• 8 Sensors• 8 Cables• 8 Waveguides to mount to inner liner• 2 NEMA and 8 protective sensor boxes• HRSG AMSTM software• Plant specific software and high signal alarm outputs• 1 year of Weekly Surveillance, a remote monitoring service• Installation, Maintenance & Operation Manuals• MISTRAS provided operator training
BEnEFITS• Early indication of a tube leak, before traditional plant methods• Reduce secondary damage• Manage power market exposure/risk• Locate leak(s) before unit comes offline• Trend severity & progression of leak with real time data• Schedule maintenance vs. forced outage• Preplan jobs with correct assets• Scalable installation options
Heat recovery steam generators (HRSGs) pose a unique set of operational challenges, due in part to their rapid startup capabilities and high operating efficiencies. Preventing HRSG tube failures (HTFs) is a priority, but complex failure paths, which are influenced by cycle chemistry or thermal transients, are difficult to understand and mitigate. Limited access and other complexities make inspection and repair of HRSGs very difficult.* Read on to discover how the MISTRAS | TRIPLE 5 AMSTM can help.
A sounding rod w/ high-temperature sensor box.
Specifications subject to change without notice. Copyright © 2013 MISTRAS Group, Inc. All Rights Reserved. www.mistrasgroup.com
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WORLDWIDE HEADQUARTERS:195 Clarksville Rd • Princeton Jct, NJ 08550 • USAT: +1.609.716.4000 • F: +1.609.716.0706E-MAIL: [email protected]
#210A-12100-02
MISTRAS | TRIPLE 5 AMS™ for HRSG
Step increase07/25
CEMS indication
07/1712A begins to increase
07/03
9A-12A small step on 07/13
Gradual increase begins 8/18
Planned Maintenance Outage 10/1
show the greatest difference from the normal background noise of the HRSG. The Triple 5 AMS™ further processes and trends the data for the operators using specialized hardware, an industrial data logger and proprietary software.
The MISTRAS | Triple 5 AMS™ system data and alarm functions are viewed and analyzed by users either locally, at the data logger, or from any remote location using VPN protocol or MISTRAS’ proprietary data replay software, Virtual AMS™. In addition, the AMS™ has the capability to interface and transmit data to and from the plant DCS system.
MISTRAS offers tech support through Triple 5 Surveillance, a remote monitoring service that
analyzes the data for acoustic changes and hardware issues. A report is sent on the status of the system by email to a group designated by the plant. A phone call is placed to the main contact and/or the control room when immediate attention is needed. A 24 hour hotline is available for high signal consultation after hours and on weekends. MISTRAS offers Daily, Weekly and Monthly Surveillance options. A one year Weekly Surveillance Contract is included with the purchase of a system.
FOR MORE InFORMATIOn:Please call 1-609-716-4077 or visit us on the web at www.mistras.triple5industries.com.
*Heat Recovery Steam Generator (HRSG) Dependability-Program 88
AMSTM
INSTALLATIONS
Sounding rod attached perpendicularly to the cold side of the inner liner of a HRSG.
Tube separation from headers is a primary area of concern for HRSG leaks.
