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BHELSONIC Manual
BHELSONIC Manual
BHELSONIC Manual
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BHELSONIC- STEAM LEAK DETECTION SYSTEM
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BHELSONIC- STEAM LEAK DETECTION SYSTEM
CONTENTS
PART-1
SECTION-1 INTRODUCTION
SECTION-4 INSTALLATION
PART-2
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SECTION-1 INTRODUCTION
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1.0 GENERAL
Early detection of steam leakage in a boiler due to tube leakage in steam coils will avoid
secondary damage to great extent. Tube failure in a boiler is considered to be one of the major
causes for boiler shut down. This problem is more pronounced in pulverized coal fired boilers,
due to ash erosion and combustion being vigorous. Tube failures are bound to increase in
present day boilers, where steam generation at high temperature is attempted to maximize
combustion efficiency, outstripping the metallurgical developments. Sonic tube leak detection
system developed by BHEL, address this issue.
The Sonic tube leak detection system works on the principle of detecting the sound waves
emanating from the steam leak, process the same and indicate the quantum of steam leak and
the location, within approximately 5M radius in the boiler from where the steam leaks. Boiler is
divided into 18 number of zones for identifying the zone in which tube leakage likely to occurs.
However, facility exists in this system to cater up to 24 zones.
In each zone, a sonic tube is mounted on the stub provided in that zone. The sonic tube is
installed at an angle of 45 degree to the vertical axis of the water wall panel and is welded to the
seal box filled with refractory. Sonic tube houses the components required for air purging
arrangement, isolation valve, heat insulated spacer & heat insulated coupling. This coupling is
used to avoid heat conduction to the sensor assembly.
The BHELSONIC system consists of acoustic sensors mounted in sonic tubes that are
connected to field amplifier units at the boiler side, and further processed with signal processing
electronics, giving output to PC through decibel scanner in addition to 4-20mA DC output of each
channel. Signal processing modules and PC are installed in the control room.
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The field amplifier PCB is mounted in the field amplifier box of size 300(B) x 200 (H)x 155(D)
protected to IP55. cable entries via gland plate are provided where the sensor connector lead is
connected. To protect the electronics, the door must be kept closed all the times.
Field amplifier box must be mounted very near to the sensor assembly. For calibration and site
tuning, approach platform for each sensor is provided.
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37 pin for decibel scanner are also mounted in the motherboard of size 426 mm x 355mm. This
mother board and modules are assembled in 19” double euro rack. Unused modules are covered
with dummy blank plates. Mother board accommodates the signal processing modules which are
interchangeable and an alarm processing module.
DECIBEL
ABSOLUTE VALUE
CIRCUIT
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NOTE: All the potentiometers are factory setting expect background suppressor
potentiometer. Don’t disturb the factory settings.
VR1
VR2
In this module, alarm delay value in time and alarm value in dB are set. Alarm delay is set by
adjusting VR1. Alarm set value is set by adjusting VR2. If any channel receives steam leak sound
more than the alarm set value for a time greater than the alarm delay set, alarm relay contact is
generated. This is normally wired to Plant annunciator. This module has a special provision. If a
contact input is given to this panel from soot blower control system to indicate any soot blower is
in operation, then the steam leak alarm contact will be inhibited during the duration of any soot
blower is in operation.
During soot blower operation, the channels near by will pick up sound from soot
blower steam spray and show sound level in dB. In case, if this sound exceeds the
alarm set value for the duration of alarm delay, the contact output will be initiated,
leading to alarm. To avoid this, the above facility is given. If wired, alarm will be
inhibited during any soot blower is in service. Alarm set value can be adjusted
from 0 to 40dB. Recommended set value is 20dB. Alarm delay range is 1 min.,
(nominal) to 10min.( nominal). This timing will not be accurate. Alarm set value and
alarm delay set time can be seen in PC in Set up screen. Adjustment can be
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Power supply unit is provided to derive +12V DC , -12V DC from the incoming 230V AC supply.
Power supply redundancy is envisaged with diode auctioneering circuit so that when one power
supply fails, another will take over automatically, without affecting the system performance.
C) DECIBEL SCANNER.
From the signal processor modules 5V DC is fed to decibel scanner. From decibel scanner, the
signals are sent to PC through serial port. In the front facia of scanner, channel number and
sound level in dB are displayed channel by channel automatically. This facility will be quite useful,
in case of PC failure. The hardware & software customisation details are given in section-6.
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Personal computer is provided in the panel. Data from decibel scanner is used to generate
different types of monitoring displays like, Bargraph, mimic, Trend, Group trend and History. The
display modes are user selectable. The hardware & software customisation details are given in
section-5.
By pressing the ‘Test’ button in the audio channel selector, the sound generators kept in all
sensor assemblies get activated and produce sound above 20dB, as long as the Test push
button is kept pressed. These sounds are processed in the system and in PC display, it can be
seen that all channels show more than 20dB sound. This can be easily visualized in “Bargraph”
mode or “Mimic display” mode of display.
By this, functioning of entire system right from sensor assemblies can be quickly checked in one
go. This test may be performed as and when needed to crosscheck the healthiness of the
system. During this test, 4-20mA output of all channels will be more than 12mA. ( Exact output is
not important but it should be more than 12mA).
Since alarm contact is initiated after a set time delay, Test push button is to be pressed
preferably for a short period say 3 to 5 seconds.
Sometimes, it may become necessary to hear the actual sound picked up by the sonic sensor
corresponding to a particular channel (after removal of combustion noise). This helps the
operator to ascertain whether steam leak is present in that location. To get the sound from a
particular sensor, switch on ‘ON& VOL’ switch, set the 3 position rotary switch “SELECTOR” in
the appropriate position (Position-1 for channels 1 to 8, Position 2 for channels 9-16, Position3 for
17 to 24).
Depress the Push button corresponding to the channel needed. LED, corresponding to that
channel goes ‘ON’ now. Increase or decrease volume control to hear the sound from the location
selected in the boiler in the speaker.
To hear another location, keep the selector switch in appropriate position and depress the
corresponding push button. Only one switch at a time in a group ( Ch 1-8, Ch 9-16, Ch 17-24)
should be pressed. When another switch in the same group is depressed, the earlier switch gets
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released through mechanical interlock. Pressing more than one switch at a time is to be avoided,
as this may damage the switch assembly.
Box details:
F). CALIBRATOR:
One no. hand held calibrator is provided with the system. Calibrator contains a power supply and
a sound source. This calibrator is pre-calibrated for a particular dB. See the value in the calibrator
name plate.
Calibrator will be useful during commissioning of the system. If the sensor or field amplifier or
signal processor module is changed due to any reason, then also, re-calibration is
recommended. Periodic calibration, say once in 3 months is recommended for all channels.
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CALIBRATION PROCEDURE
1. Keep the PC display mode to “BARGRAPH display”
2. Close the isolation valve in the sonic tube corresponding to the channel to be calibrated.
3. Now, gently remove the sensor by unscrewing. Ensure the cable connection is in tact.
4. Connect the AC mains supply to calibrator.
5. Switch on the calibrator.
6. Now press the push button “PS” for a while. Now the sound from the calibrator will be
heard. When you leave the push button, sound stops. This is a calibrated sound.
7. Now insert the sensor into the socket portion of the calibrator.
8. Now press the push button.
9. The sound value in dB shown in MIMIC drawing corresponding to this channel should be
the calibrated value indicated in the calibrator +/- 1dB.
10. If this is O.K., the selected channel’s calibration is O.K.
11. If not, tuning has to be done in field amplifier unit corresponding to the selected channel.
Open the field amplifier box, so that field amplifier electronic module is visible. Locate
potentiometers P1(fine adjustment) and P2( coarse adjustment).
12. Keep pressing the push button in calibrator. Adjust P2(coarse) and P1(Fine), till the dB
reading in PC MIMIC display comes within +/- 1dB of the calibrator dB.
13. With this, calibration of one channel is over.
14. Switch off power supply to the calibrator and connect back to sonic tube by screwing
gently.
15. Open the isolation valve.
16. Now this channel is through for use.
Note:
1. You may need walkie-Talkie or any other plant communication mechanism to get the dB
value read from the PC display in the panel located in control room/ control equipment
room.
2. If the calibration could not be achieved by the above procedure, the owner may contact,
BHEL/Trichy for calibration/ servicing.
3. The calibrator itself may need recalibration say once in 2 years. BHEL/ Trichy may be
contacted for details.
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BHELSONIC- STEAM LEAK DETECTION SYSTEM
SECTION – 4: INSTALLATION
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The sonic tube assembly is required to be mounted in identified locations of the boiler which are
already provided with seal box arrangement with the opening for guiding the sound waves from
the zone into the sonic tube and finally to the sensor mounted at the end of sonic tube.
Before drawing the Sonic Tube from the stores, the following points must be checked.
When the installation of the sonic tube has been completed, precautions must be taken to protect
it against damage during the installation of adjacent plant equipment / pipe work etc.
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Before drawing Field Amplifier Unit from store, the following points should be checked:
The field amplifier Unit is to be placed nearer to the Sonic sensor. Ensure by examining the
internals that the correct unit is drawn from store, and that it is undamaged and in a suitable
condition for installation to start.
The field amplifier unit is provided with fixing holes in the rear vertical fac e for bolting it to the wall
or suitable support structure. Transport sonic amplifier unit to location. Bolt and position carefully
on prepared surface. Fix using bolts, nuts and washers or equivalent fastenings. When the unit
has been positioned and bolted in place, adequate precautions must be taken to ensure that it is
protected against accidental damage during the installation of adjacent plant / equipment and pipe
work or the completion of any local building work. The unit is to be wired to the respected sensors
and is to be positioned so that the length of any cabling connecting the unit to sensors does not
exceed 10 meters.
The junction boxes are provided with fixing holes in the rear vertical face for bolting them to the
wall or suitable support structure. Transport junction boxes unit to the location. Position carefully
on prepared surface. Fix using bolts, nuts and washers or equivalent fastenings. When the unit
has been positioned and bolted in place, adequate precautions must be taken to ensure that it is
protected against accidental damage during the installation of adjacent plant / equipment and pipe
work or the completion of any local construction or repair work.
Before drawing System cabinet from store, the following points should be checked:
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Ensure by examining the internals that the correct unit is drawn from store that it is undamaged
and in a suitable condition for installation to start.
The System Cabinet is provided with fixing holes in the bottom face for bolting it to the floor.
Transport the system Cabinet to the identified location and position carefully on prepared
surface. Fix the cabinet to the surface using bolts, nuts and washers or equivalent fastenings.
When the unit has been pos itioned and bolted in place, adequate precautions must be taken to
ensure that it is protected against accidental damage during the installation of adjacent panel /
equipment or any local construction and repair work.
4.5 CABLING
• That the system cabinet and junction boxes ready for cabling.
All the above works, if carried out by an Electrical Contractor shall be subjected to inspection for
workmanship and accuracy by an appropriate authority.
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This wiring is to be carried out using pre fabricated cable supplied with the system. These are
terminated with 6 pin connectors at sensor end and provided with crimp pins at the sonic
amplifier unit end. The conductors should be identified with suitably marked ferrules at each end.
The cables from the sensor, where it enters the base of the field amplifier unit, must pass through
glands provided. The wiring within the enclosure is to be run neatly and terminated as prescribed
above (crimp pins).
This wiring is to be carried out using 8 pair 0.5sq.mm shielded cables supplied with the system.
These are terminated with crimp pins. The conductors should be identified with suitably marked
ferrules at each end.
The cables from the system cabinet where it enters the base of the respective junction boxes,
must pass through glands provided. The wiring within the enclosure is to be run neatly and
terminated as prescribed above (crimp pins).
The cables from the system cabinet, where they enter the base of the junction boxes, must pass
through the cable glands provided at the base of junction boxes. The wiring within the enclosure
is to be run neatly and terminated as prescribed above (crimp pins).
All the above works, if carried out by an Electrical Contractor shall be subjected to inspection for
workmanship and accuracy by an appropriate authority.
This wiring is to be carried out using 4 pair 0.5 sq.mm cable supplied with the system. These are
terminated with crimp pins. The conductors should be identified with suitably marked ferrules at
each end.
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The cables from the junction boxes, where they enter the base of the field amplifier unit, must
pass through the cable glands provided with the unit. The wiring within the enclosure is to be
made neatly and terminated as prescribed above (crimp pins).
Power supply wiring of System cabinet to plant UPS is to be carried out using the 3-core
1.5sq.mm cables supplied with the system. These are terminated with crimp pins. The
conductors should be identified with suitably marked ferrules at each end.
The cables from the system cabinet, where it enters the base of the plant UPS, must pass
through the cable glands provided. The wiring within the enclosure is to be run neatly and
terminated as prescribed above (crimp pins).
This wiring is to be carried out using the 2-pair 0.5 sq.mm cables supplied with the system.
These are terminated with crimp pins. The conductors should be identified with suitably marked
ferrules at each end. The wiring within the Enclosure is to be run neatly and terminated as
prescribed above (crimp pins).
The cables from the system cabinet, where it enters the base of the plant UPS, must pass
through the cable glands provided.
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SECTION-5
TROUBLESHOOTING &
MAINTENANCE
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A. MAINTENANCE.
1. Press the test push button in the panel periodically, say once in a week or as and when
required for 3 to 5 seconds and observe that all channels show more 20 db ( Go to MIMIC
screen on BAR graph screen to view this.
2. Periodically, say once in a week or as and when required, based on experience purge the
sonic tube by opening the valve in the pneumatic purge line for 5 to 10 seconds or as
required after getting experience. Make sure ball valve is kept closed during purging
operation, in order protect the sensor microphone. Sufficient air pressure is also to be
ensured. Ball valve should be kept opened, after purging completion. Follow this purging
procedure for all sensor locations. If this is not done regularly for a long time and sonic tube
clogging becomes acute, poking may be needed.
3. Personal computer supplied is similar to other personal computers available in the plant,
except for a special SCADA software . Follow the same maintenance procedure for this
personal computer also, similar to maintenance of other personal computers in the plant.
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B.TROUBLE SHOOTING
2. Indication lamps in power supply (For 1. Check & replace the DC fuses. To be checked for
+12v and –12v ) not glowing. availability.
2. If problem still persists, power supply needs
servicing (system will function properly, even if one
power supply is all right )
3. While pressing ‘Test’ push button, dB 1. Check ± 12V indicating LED lamps are
indication is not coming in any channel. glowing in field amplifier. To see this, open the door.
Check and ensure cable connection is intact.
6. PC working but data not getting 1. Observe dB scanner is showing the channel
updated. number and dB value sequentially from first channel
to last channel automatically. Press the test PB in
alarm procuring modules and watch this new dB
values in all channels. If the scanning or updating is
not taking place, dB scanner needs servicing.
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SECTION-6:
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Dos
ENSURE PROPER CONNECTOR SEATING AND SCREWS FIXED AT TOP & BOTTOM OF
THE RACK AFTER INSERTING ANY MODULE
Don’ts
KEEP THE FIELD AMPLIFIER BOX OPEN CONTINUOUSLY
USE THE PC FOR ANY OTHER PURPOSE, OTHER THAN THIS INTENDED PURPOSE,
BY LOADING ANY OTHER SOFTWARE THROUGH MEANS LIKE FLOPPY DISK, CD,
THUMBNAIL DRIVE ETC., WHICH MAY RESULT IN VIRUS ATTACK/ DISTURB THE
SOFTWARE AND COLLAPSE THE FUNCTIONING OF PC OR CITECT HMI/ SCADA.
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