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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

Optris BR 400

sku Product SKU:  OPT-BR-400

Knowing the exact value of the radiation temperature is essential for the calibration process. It can be measured by either using a contact thermometer (in combination with the determination of the emissivity) or a transfer standard infrared thermometer. This value can then be used to determine the device constant for an initial calibration of the infrared sensors. In order to conduct a post-calibration by customers or local calibration facilities, the calibration temperature should be near the temperatures which occur at the respective applications.

Optris makes use of a transfer standard radiation thermometer CTlaser-PTB (see figure) to measure the radiation temperature of a reference source. The CTlaser- PTB is based on the IR thermometer optris CTlaser. The CTlaser-PTB needs to be traceable to the international temperature scale from 1990 (ITS-90). Thus, it is calibrated by the PTB (German national metrology institute) on a regular basis. ITS-90 is a very good approximation of thermodynamic temperature. It is based on 17 well-reproducible fixed values such as melting points of highly pure metals. Within the framework of ITS-90 the CTlaser-PTB is compared to national temperature standards from the PTB. This comparison within a closed chain of comparative measurements with a known uncertainty in measurement takes place on a regular basis.

Based on the CTlaser-PTB, Optris produces the CTlaser- DCI as a high-precision reference IR thermometer for its customers. The DCI units are produced with pre-selected components supporting high stability of measurement. In combination with a dedicated calibration at several calibration points the CTlaser-DCI achieves a higher accuracy than units from series production.

The optics of an IR thermometer is described by the distance-to-spot-ratio (D:S). Depending on the quality of the optics a certain amount of radiation is also received from sources outside the specified measurement spot. The maximum value here equals the radiation emitted by a hemispheric radiant source. The respective signal change in correlation with a resize of the radiation source is described by the Size-of-source effect (SSE).

As a result of this correlation all manufacturers of IR thermometers use accurately defined geometries for the calibration of their units; meaning depending on the aperture of the radiation source (A) a distance (a) between the IR thermometer and the reference source is defined. Thus, the value specified in datasheets and technical documentation as a measurement field is, in general, a certain defined percentage of this radiation maximum – values of 90 % or 95 % are common.

ZAR 54080,0000

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


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