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Inspecta-III

Inspecta III

sku Product SKU:  INSPECTA-III

Locally designed and engineered, based on over 35 years of boiler steam tube leak detection experience in South Africa, Australia and Europe, the Inspecta III uses acoustic detection technology to  detect tube leaks less than 2mm in diameter in the large boiler structure.

The first 10 systems, Inspecta-FFT were sold to Eskom Matla & Duvha in 1985.

Major features include:

  • Backward compatibility with existing Inspecta field sensor arrays and plant interfaces.
  • Providing a new platform using current industry-standard technologies with modern capabilities.
  • New sensor array that minimises installation work and modification to the boiler (future).

The Inspecta III is aimed at large thermal boiler installations in the range 200 MW to 900 MW but can also be tailored for smaller facilities. 

Its extensive diagnostic facilities enable tube leaks to be detected at a very early stage (1mm to 2mm) and the leak progression to be followed. This allows maintenance to be planned and scheduled at an appropriate time instead of suffering an unplanned breakdown and its many bad consequences.

The Inspecta III has been designed to evolve from a basic steam leak detection system with new modern features to an advanced expert system. This will provide effective management information to enable plant operators to efficiently plan and implement required shutdowns and necessary repairs.

The system implements various utility and power station Distributed Control System(DCS) interfacing requirements. These range from 4 to 20 mA to industry standard protocols, such as Modbus and Ethernet.

The figure below shows the Inspecta III system configuration. Built using standard 19”rack technology, the system can either be fitted into a standard 19” rack or used as a desktop version.

InspectaIIConfigured

Sensor Network

The acoustic sensor network is fitted to particular points on the boiler. These are selected to ensure adequate boiler coverage.

The Inspecta III system utilises sophisticated sensors specifically designed for this application. Sensors can also be fitted with automatic air purging systems to reduce routine maintenance to clear acoustic waveguides of boiler fly ash.

Connection to the sensor network is via a cable network connection.

Inspecta III Server

The sensors connect to a central computer, which captures, analyses and displays the received data and communicates decisions based on the information captured by the sensor network.

The industry standard server runs a variation of the Linux Operating System and connects to the advanced sensor network via the industry standard Ethernet protocol.

Captured data is stored in an SQL and JDBC relational database, processed and conclusions appropriately displayed to the operator.

Connection to Power Station Information System

Connection into the facility or power station information system is either via a separate Ethernet connection or, in the case of an existing DCS, via a standard  industry interface such as Modbus.

This allows the Inspecta III to interface to both modern and older existing utilities as necessary.

Backward Compatibility

Realising that many existing installations will want to upgrade to the new Inspecta III Server and take advantage of the many new features, without incurring unnecessary costs, the new system has been specifically designed to interface with an existing Inspecta sensor network.

By means of an Inspecta Plant Interface Unit (PIU), signals from existing sensor networks are converted to Ethernet and connected to the Inspecta III Server.

Advanced diagnostics that are built into the PIU allow effective remote fault location and diagnosis.
 

Analog Sensor Network

The sensor network consists of transducers mounted at selected points on the boiler structure. Acoustic sensors are typically mounted on boiler inspection doors for convenience. 

 

FFT-HA3

Wired Acoustic Sensor (HA3 Audio sensor)

This is the existing legacy product installed at existing Inspecta system sites.

FFT-PVC

Pipe Set

The PVC pipeset is bolted to a customer supplied stub pipe which terminates approx.. 1m away from the boiler side wall. The PVC pipeset is mounted to the steel flange with airtight gasket supplied by Instrotech. The HA3 audio sensor is attached to the PVC pipeset with a QUICK Release coupling to facilitate easy maintenance and cleaning of soot / fly ash from the Acoustic wave guide pipe.  Positioning of the stub pipes is determined between the supplier and operating & maintenance staff of the customer.

InspectaAPS

Automatic Purge System (APS)

The APS keeps the Inspecta sensor pipe sets sufficiently clear of fly ash such that the performance of the Inspecta steam leak detection system is continually effective without requiring routine pipe cleaning maintenance. It operates autonomously and reliably once setup, requiring minimum routine maintenance. The system has built-in diagnostics and communicates  any detected faults to the control room.      


 

ZAR 0,0000

IMG-KEL-DRX22-CTD-1

Keller DCX 22 CTD

sku Product SKU:  KEL-DCX-22-CTD

The DCX-22-CTD data loggers measure conductivity and temperature as well as pressure, along with the depth of bodies of water. The integrated Pt1000 achieves an accuracy of ±0,1 °C, and the conductivity can be measured at ± 2,5% of the selected range (0,2 / 2 / 20 / 200 mS/cm). Thanks to their long-life battery, they can keep recording measurement results for years (up to 10 years at a rate of one measurement per hour). The logger can be configured using the supplied software (measurement interval, incident management, delayed measurement start etc.) and data that has been read can be displayed in a graph or chart, corrected using air pressure values, converted into fill levels or other units, and exported.

The CTD versions of the DCX-22 range are autonomous battery-operated data collectors made of stainless steel. Requiring little maintenance, they record the water level (pressure), tempe- rature and conductivity over long periods. CTD stands for Conductivity, Temperature and Depth.

This data sheet specifies the additional conductivity measurement function which distinguishes the CTD version from the standard DCX-22. The pressure and temperature specifications are set out in detail in the data sheets for the DCX-22AA and DCX-22(SG/VG).

Conductivity is increasingly being monitored in conjunction with depth measurements, in which changes in water quality and depth are required to be detected simultaneously. Thus it is possible to detect contamination caused by salt water, waterborne particles or general pollutants when measuring groundwater levels.

KELLERʼs KOLIBRI Desktop programming and readout software is used to select a conductivity range (0...0.2 mS/cm, 0...2 mS/cm, 0...20 mS/cm or 0...200 mS/cm) and set the temperature coefficient for the medium. This process produces compensated conductivity measured values standardised at 25 °C.

DCX-22AA-CTD
The DCX-22AA-CTD data collector records groundwater levels using the AA (absolute- absolute) measurement method, whereby fluctuations in atmospheric pressure are measured and compensated for by the watertight atmospheric pressure sensor with its stainless steel dia- phragm. The advantage of this measurement method is that no humidity-sensitive capillary tube is required. As well, it is not required that the DCX-22AA-CTD be removed from the immersion tube in order to extract the data.

DCX-22-CTD
In the DCX-22-CTD, the sensor, electronics and battery are contained within the same housing. The data collector needs to be withdrawn from the immersion tube in order to extract the data. The DCX-22-CTD uses an absolute pressure sensor. For long-term measurements, where the impact of atmospheric pressure fluctuations is to be compensated, a second DCX, acting as a barometer, is placed at the surface to record changes in atmospheric pressure. The pressuredifference or, as appropriate, the water level is then calculated in the Kolibri Desktop Software by subtracting both measured values.

DCX-22(SG/VG)-CTD
The DCX-22SG/VG-CTD versions have a cable outlet with a readout plug, which is fixed to the surface of the measuring point with a locking disc. This means that the data logger does not have to be pulled out of the measuring point to read out the data. In the VG version (reference pressure measurement), the reference equalisation capillary tube in the cable is inserted until the read-out connector, where the reference opening protected by a Gore-Tex® diaphragm is located.

ZAR 0,0000

Keller Series PD-39X

sku Product SKU:  KEL-39Xs

The Series PD-39 X does not measure the differential pressure directly – instead, it uses two absolute pressure sensors to take the measurement indirectly. As well as reducing costs, this differential pressure transmitter is also more robust in relation to unbalanced (one-sided) overloading. The differential pressure range should be at least 5% of the standard pressure range. Each pressure side has two pressure connections, so the

Pressure measurements can be displayed and recorded on PC or Laptop with help of the software ControlCenterSeries30 (CCS30) and a seriel interface cable. Export of recordings to usual file formats possible. Up to 128 devices can be connected together into a KELLER Bus-system.

The Series PD-39 X does not measure the differential pressure directly - instead, it uses two absolute pressure sensors to take the measurement indirectly. As well as reducing costs, this differential pressure transmitter is also more robust in relation to unbalanced (one-sided) overloading. The differential pressure range should be at least 5% of the standard pressure range. Each pressure side has two pressure connections, so the PD-39 X is easy to use in pressure lines

So that the differential pressure can also be measured exactly if the standard pressure range/ differential pressure ratio is high, this series also features the tried-and-tested microprocessorbased technology that is used in Series 30 X. All reproducible pressure sensor errors (i.e. nonlinearities and temperature dependencies) are entirely eliminated thanks to mathematical error compensation. The sensor signals are measured with a 16-bit A/D converter, so the individual standard pressure ranges can be measured to an accuracy of 0,05%FS throughout the entire pressure and temperature range.

Digital Interface

The transmitters have a bus-compatible two-wire RS485 half-duplex interface which is modelled on the ”MODBUS RTU”. KELLER offers interface converters to RS232 or USB for use here. The READ30/PROG30 program and the protocol are freely available. The interface offers these capabilities:

- Readout of pressure and temperature values for both sensors. This allows readout of the diffe- rential pressure as well as the two standard pressure ranges.

- Calibration of zero points and amplification.

- Scaling of the analog output to different pressure ranges or units.

- Configuration settings such as measurement rate, low-pass (LP) filter, bus address, etc.

- Readout of information such as serial number, compensated pressure and temperature ranges, etc.

Analog Output

The analog output is freely scalable via the interface. For flow measurements, the root of the differential pressure can also be outputted. The calculated value can be outputted via an analog interface (0…10 V or 4…20 mA).

ZAR 0,0000

Kel-DCX-ECO

Keller DCX18 ECO

sku Product SKU:  KEL-DCX18-ECO

The DCX-18 ECO is an autonomous, rechargeable battery powered instrument. It features a stainless steel 18 mm in diameter housing designed to record pressure (water depth) and temperature over long periods at a very economical price. Its small size, rechargeable battery, fully welded housing and the relative sensor option are just a few of the many advantages provided by the DCX-18 ECO.

The electronics employ the latest microprocessor technology which give high accuracy and resolution for the pressure and temperature signals. The measured values are mathematically compensated for all linearity and temperature errors of the pressure sensor. The use of a non-volatile memory for data storage ensures high data security.

DCX-18 ECO

The sensor, electronics and the rechargeable battery are housed in a fully welded stainless steel tube for submersible deployment. For data read-out, the DCX-18 ECO must be recovered from the measurement point. The end cap, sealed by two O-Rings, must then be removed to access the serial interface. The DCX-18 ECO works with an absolute pressure sensor. In shallow water depths where the influence of barometric pressure changes should be considered, it is recommended that a second data logger (Baro) is placed at the surface, to record the barometric pressure. The PC then calculates the differential pressure resp. the water depth by subtracting the two measured values.

DCX-18 ECO with cable (DCX-18 ECO SG or DCX-18 ECO VG)

An optional cable is available for the DCX-18 ECO, enabling data retrieval or configuration and charging the battery without removing the data logger. For relative measuring devices, the cable incorporates a capillary tube which enables venting the relative sensor.

Rechargeable Battery:

The DCX-18 ECO is charged over the USB connection with the K-104M converter connected to PC. For fast charging, connect the power supply unit or the car charging adapter to the converter. The charge status is displayed in the logger software

ZAR 0,0000

Keller DCX-25PVDF

Keller DCX-25PVDF

sku Product SKU:  KEL-DCX-25PVDF

The DCX-25 PVDF is an autonomous, battery powered instrument designed to record water depth (pressure) and temperature over long periods. The housing is made of polyvinylidene fluoride and the sensing diaphragm is available in either Hastelloy C-276 or titanium 6AL-4V. This combination of wetted materials ensures compatibility with even the most aggressive media

This data collector (Ø 25 mm) integrates a pressure sensor, electronics and battery in one housing. The electronics employ the latest microprocessor technology, which give high accuracy and resolution for the pressure and temperature signals. The built-in pressure sensor is mathematically compensated for all linearity and temperature errors. The use of a non-volatile memory ensures high data security.

The DCX-25 PVDF works with an absolute pressure sensor. For installation, the data collector is secured by a suspension cable and immersed into the media to be measured and must be recovered for data readout. In shallow water, where the influence of barometric pressure changes should be considered, it is recommended that a second data logger (e.g. DCX-22 Baro) is placed at the surface to record the barometric pressure. The Logger PC software then calculates the water depth by subtracting the two measured values. The housing of the data logger can be opened easily without any tools, thus allowing quick access to the replaceable battery and the interface connector for configuration and data download.

Interface with a PC is accomplished using one of Keller’s converter cables which are available in either RS232 connection (K103A) or USB connection (K104A). The necessary converter drivers are included with converter purchase, along with the Keller Logger software. This intuitive software provides the capability to customize the instrument, as needed, for each installation. Users can configure the DCX-25 PVDF to record at fixed time intervals, using fixed or eventbased start times, in user-selectable measurement methods to ensure that only the most useful and meaningful data is collected and stored.

For applications that do not require highest compatibility with aggressive media, Keller offers the DCX-16, DCX-18, DCX-22 and the DCX-38.

ZAR 0,0000


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