INSPECTA FFT

BOILER TUBE LEAK DETECTION SYSTEM

OPERATING & INSTALLATION MANUAL

FOR THE BASIC SYSTEM

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1. SYSTEM REQUIREMENTS
1.1 INSPECTA FFT---------------------------------------------------------------------------------------------------------------------------------------------- 3

1.2 VGA GRAPHICS MONITOR ---------------------------------------------------------------------------------------------------------------------------- 3

1.3 DOT MATRIX 80 COLUMN GRAPHICS PRINTER ----------------------------------------------------------------------------------------------- 3

1.4 INSTALLATION REQUIREMENTS -------------------------------------------------------------------------------------------------------------------- 4

2. INSTALLATION INSTRUCTIONS
2.1 BOILER REQUIREMENTS------------------------------------------------------------------------------------------------------------------------------- 4

2.2 FIELD CABLING -------------------------------------------------------------------------------------------------------------------------------------------- 5

2.3 MULTIPLEXER / COMPUTER CABLING------------------------------------------------------------------------------------------------------------ 5

2.4 ANCILLARY EQUIPMENT CABLING----------------------------------------------------------------------------------------------------------------- 6

2.5 MOUNTING --------------------------------------------------------------------------------------------------------------------------------------------------- 6

3. OPERATING INSTRUCTIONS
3.1 INTRODUCTION -------------------------------------------------------------------------------------------------------------------------------------------- 7

3.2 PURPOSE ---------------------------------------------------------------------------------------------------------------------------------------------------- 7

3.3 SAFETY8

3.4 COMPONENTS AND LAYOUT ------------------------------------------------------------------------------------------------------------------------- 8

3.5 SYSTEM WORKING PRINCIPLE --------------------------------------------------------------------------------------------------------------------- 9

3.6 INTERPRETATION OF ALARMS ------------------------------------------------------------------------------------------------------------------- 13

3.7 ALARM OUTPUTS AND REMOTE CONTROL -------------------------------------------------------------------------------------------------- 13

3.8 ROUTINES ------------------------------------------------------------------------------------------------------------------------------------------------- 14

4. MAINTENANCE REQUIREMENTS
4.1 FIELD CALIBRATION ----------------------------------------------------------------------------------------------------------------------------------- 15

4.2 INSPECTA FFT CALIBRATION PROCEDURE -------------------------------------------------------------------------------------------------- 16

4.3 SYSTEM FAULT FINDING PROCEDURE--------------------------------------------------------------------------------------------------------- 17

4.4 PRINTER AND CONTROL ROOM EQUIPMENT ------------------------------------------------------------------------------------------------ 18

5. Document revisions

6. Appendix

6.1 FLANGE DRAWING

6.1 ALARM INHIBIT ZONES

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 1.1 INSPECTA FFT
ᇏ INSPECTA FFT Multiplexer / Computer and Control Panel
List of modules. See Layout of Electronic Modules.
MUXCPU Single board computer
card as detailed below.
MUXPSU Switch mode power supply
for computer.
MPUADC Analogue/Digital converter
card.
PSUMTR Linear power supply for 32 field sensors
MUXMPU Multiplexer card for CPU inputs
MUXAMP Multiplexer card for audio inputs
MUXISO Input 16 way isolator card(s)
MUXRLY Alarm relay and digital input card
MUXFPU Operator panel with speaker, can be remote

CPU details: Commercial plug-in single board computer card with the following minimum
specifications :

486 with co-processor or Pentium processor

16Mb RAM
16MB Disk on chip, flash memory
RS232 I/O ports for serial printer
VDU driver. (can be separate card)
Real time clock
Commercial VGA graphics card (if not on CPU)
ᇏ INSPECTA FFT Sensor / Head amplifiers
In cast Aluminium IP65 housing with quick release PVC coupling and electrical
plug connector. Sensor capsule replaceable. Quantity depends on boiler /
customer requirements.
ᇏ INSPECTA FFT PVC Wave guides.
Includes ND40 Flange, 50mmID PVC Class 9 pipe, Y-piece,
quick release coupling and 50mm Ball Valve. Quantity depends on
boiler / customer requirements.

1.2 VGA GRAPHICS MONITOR

ᇏ Any plug & play CRT VGA computer monitor.

1.3 DOT MATRIX 80 COLUMN GRAPHICS PRINTER (Serial RS232)

ᇏ Any 80 column dot matrix printer with serial printing capabilities e.g. EPSON LX300.

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 1.4 INSTALLATION REQUIREMENTS
The following requirements are normally customer supply, but can be supplied by us by special arrangement.
ᇏ Stub pipes with 50mm ID flanges, mounted through the boiler wall or inspection hatches
(See Appendix A for flange drawing).
ᇏ One or two field mounted junction boxes for marshalling the single sensor cables on either side of
the boiler, to multi-core cables for the transmission of the signals to the control room.
ᇏ Two pair, 0.5mm stranded copper, overall screened cable for the connection of the INSPECTA FFT
Sensors to the junction boxes. Maximum OD 7mm to fit into plug connector.
ᇏ Multi-core cable from the junction boxes to the INSPECTA FFT Multiplexer / Computer in the control
room. Three pairs per two sensors. 0.5mm stranded copper, individually screened cable.

2.1 BOILER REQUIREMENTS

ᇏ The positioning of the Stub Pipes is determined between the supplier of INSPECTA FFT; the operating
and maintenance staff of the customer, and can include the boiler manufacturers.

NOTE: When finalising the exact position of the INSPECTA FFT sensor mounting points, stay clear (
> 2m) of other sound sources, e.g. soot blowers, pyrometers, etc. Allow for boiler expansion
and contraction so that the Stub Pipes and the Sensor/Head Amplifiers do not touch the
supporting structure or external boiler pipework.
Ensure that the mounting plates to which the Stub Pipes are attached, are strong enough to prevent distortion
when they become hot. We recommend at least 10mm plate with adequate gussets on to
the Stub Pipes (a box section with fire clay filling seems to work very well).
ᇏ Pipe work fitting and tube work manipulation is carried out by the Boiler supplier or Boiler maintenance
staff.
ᇏ Stub Pipes can be fitted through the boiler side walls by means of tube manipulation, or by
modification of the existing portholes or inspection hatches. We have experienced staff who can help
with detailed requirements. (See figure 1 and 2)

1. Boiler Wall Mounting 2. Porthole mounting

ᇏ The customer-supplied Stub Pipe should terminate approximately one metre from the boiler side wall,

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 with a standard steel pipe flange, 50mm ID as per drawing in this manual.
ᇏ The PVC Microphone Mounting Pipe work is bolted to the steel flange with an airtight gasket supplied
by ourselves.
ᇏ The PVC coupling MUST point up or if there is not space then sideways, NEVER down.

ᇏ The INSPECTA FFT Sensor/Head amplifier is then attached to the PVC Sensor Mounting Pipe work
with a Quick Release Coupling to facilitate easy maintenance and cleaning of soot from the Acoustic
Listening Pipe.

2.2 FIELD CABLING

ᇏ Each INSPECTA FFT Head Amplifier has a 4-terminal electrical connection for the power supply and
output signal.The output signals are galvanically isolated from the electronics. The connector on the
cable side is a female straight type BINDER 002 9904031004. Pin #1 = 0Vdc, #2 = 24VDC, #3 =
signal, #4 = signal. The cable shield is not connected to the plug or microphone.
ᇏ The multi-core, overall screened cables are used from the INSPECTA FFT Head Amplifiers to the
marshalling junction boxes. Up to sixteen sensors may be mounted on each side of the boiler - these
are cabled to the appropriate junction boxes.
ᇏ The forty-pair, 0.22mm, overall screened cables are used to connect the junction boxes to the
control room. Low impedance, 600 ohm audio signals are used to prevent interference from other
electrical noise that may be present in the boiler area.
ᇏ The multi-core cabling is terminated at the plug-in screw terminals located on the back of the
INSPECTA FFT Multiplexer / Computer housing.

2.3 MULTIPLEXER / COMPUTER CABLING

ALL CONNECTORS ON BACK PLANE OF MULTIPLEXER COMPUTER

Mains Supply
ᇏ A standard IEC mains socket (computer type) with fuse and EMI filter is provided.

ᇏ Check supply voltage and fusing as per legend. If incorrect supply internal links have to be re-
soldered.
ᇏ This must be carried out by suitably qualified personnel with power disconnected before
removing cover.
ᇏ Fuses must be of the `slow blow' type.
Field Connections
ᇏ All field wiring is terminated along the lower plug in terminal rail.

ᇏ Termination is in blocks of four sensors with a common 24VDC current limited power supply
for each block.
ᇏ Connections are clearly marked along this terminal rail.

ᇏ Sufficient terminals are installed for a full 16 way system or for a full 32 way system.

ᇏ The software initial set-up procedure will determine how many sensors are functional and can
be changed up to the full 16 or 32 way.

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 Control Room Interface
ᇏ Four potential free inputs and four relay changeover outputs are available with plug-in screw
terminals.
ᇏ The standard input configuration is for INHIBIT ALARM which inhibits all alarm outputs and
internal audio alarm, and ALARM ACCEPT which cancels the internal audio alarm only.
ᇏ The other two inputs are spare and can be used for additional special functions such as zone
inhibit.
ᇏ The relay outputs are used for TUBE LEAK ALARM, PRINTER ALARM, LOW LEVEL AND
POWER FAILURE.
ᇏ These outputs are all fail-safe, that is, they are energised in a safe condition and drop out on
alarm or power/electronic failure.

2.4 ANCILLARY EQUIPMENT CABLING

Mains Supply
ᇏ Check supply voltages before switching on. Cable power to visual display unit and printer.

ᇏ There are solder links inside the multiplexer / computer box for 110/220 VAC selection.
Visual Display Unit
ᇏ Use standard connections to multiplexer / computer.
Printer
ᇏ The system is designed to use a dot-matrix 80 column printer for graphic records of screens
or audio signatures.
ᇏ In order to allow for distances of more than two meters, serial printers are used.

ᇏ Protocol = IBM pro printer II, baud = 9600, parity = even, data bits = 8, stop bit = 1.

Inspecta Ver 4 Ver 3 Printer

Transmit data #101 #3 #3 Rx Data

Clear to send #102 #8 #20 DTR

Signal ground #103 #5 #7 ground

no connect no connect #1 screen

Connector Three pin DSUB 9 FEMALE DSUB 25 MALE

Seikosha Dip Switch #1=11110000, Dip Switch #2=110110

2.5 MOUNTING

ᇏ The multiplexer / computer hardware is designed to be mounted into the power station control console
(or back of panel) with only the screen and operator panel visible.
ᇏ Operator panels can b remote mounted with a maximum distance of 5 meters cable.

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3.1 INTRODUCTION
The conventional method of detecting tube leaks such as monitoring make-up water, mass balancing or
depending on the human ear to recognise a sound change, are not sufficiently sensitive or reliable on l
large boilers. By using these methods the leak is often large enough to have already caused serious
consequential damage - sometimes to an entire boiler face.

Research on Acoustic Tube Leak Detection for power station boilers started during the 1970's and has
since become the most advanced method of tube leak detection world-wide.

Detection was initially achieved utilising filters to separate the normal background noises from the sound
of a tube leak. With the advent of modern digital sound analysis techniques - namely Fast Fourier
Transforms (FFT) - frequency spectrums are generated for each audio sensor. The analysis of these
spectrums for a combination of frequencies determines the value of the alarm in percentage when a
sensor channel is above a pre-set alarm value for a pre-set time when the leak alarm relay is activated.

The computer scans up to 32 sensor points situated around the boiler. Each point is analysed for the
sound made by escaping steam. A detected leak is graphically displayed on screen in the form of an
audio spectrum and an alarm Bar Graph.

Mimic displays show where the leak has occurred and Trends can indicate how fast the leak is growing.
Alarm outputs can attract the operator’s attention and be coupled into the station logging equipment.

3.2 PURPOSE
With computer advances in the field of voice recognition - applied to industrial tube leak detection to
`listen' to the sound within the combustion chamber - a highly sensitive method has been developed
which can detect leaks of less than 2mm in diameter in 600 MW boilers. These systems are field-proven
and have provided early warning leak detection on many occasions at such an early stage that no
consequential damage has occurred.

This advance warning allows for planned shut-downs and generally reduces downtime to a matter of days
instead of weeks.

Experienced plant operators also make use of the system to listen for other abnormal operating sounds
such as faulty soot blower valves, exterior flange or pipe leaks and, in one instance, an explosion on start-
up which caused a split down the wall. The system adds SOUND to the operator’s repertoire. One
operator said that not having a tube leak detection system was like driving a car without a rear view mirror.

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 3.3 SAFETY
Power supplies to the computer, printer and multiplexer housing are from the mains supply, 110 or 220V
AC, and should only be handled by qualified electrical personnel. Covers on the above equipment should
not be removed whilst power is connected.

All field wiring is low voltage isolated DC and designed to be short circuit proof. It can be handled with
complete safety.

When carrying out clearing of the sensor stub pipes (the procedure is given in routines) care must taken
to stand to one side when opening the cleaning and rodding valve in case the boiler pressure is positive.
In this instance hot air could blow out the pipe resulting in injury.

3.4 COMPONENTS AND LAYOUT

Attached to this operating manual are photographs and drawings:
3.4.1 Boiler Schematics Showing Tube Leak Detector Sensor Layout
This schematics shows a typical sensor layout with emphasis on the protection of the super-
heater area. Other boiler layouts may vary and often the economisers are also covered.

The Black circles represent microphone sensors on the left side of a boiler.

Note: The schematics are all viewed from the left side. Microphone placements are duplicated on the right or opposite side.

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 3.4.2 Stub Pipe Photographs
Photographs are shown of a steel Stub Pipe with support flange mounted through the boiler wall
and a Stub Pipe through a porthole. These are mounted at an angle to allow any condensate to
run back in to the boiler. Up to 32 Stub Pipes may be fitted to the boiler depending on size and
coverage needed. These pipes carry the combustion chamber sounds out to the sensors.

1. Boiler Wall Mounted 2. Porthole Mounted

3.4.3 Inspecta-FFT Insulated Mounting Pipe work

This PVC flanged pipe with Y-piece and Cleaning\Rodding valve is attached to the steel Stub
Pipe. The pipe is made of PVC to prevent heat being conducted from the Stub Pipe to the
Sensor. The Sensor/Head amplifier is a dust and moisture proof cast Aluminium housing
containing the sealed audio sensor and an output amplifier. The quick release coupling simplifies
sensor exchange for maintenance or repair.

1. HA3 Audio Sensor Head Amplifier. 1. Insulating PVC-Pipework Assembly

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3.4.4 Inspecta-FFT Block Diagram
This diagram shows how the electronic components are coupled together. The field mount
Sensor/Head Amplifiers are all connected to the Multiplexer, an electronic switch that selects
each Sensor in turn for the Computer to analyse the sound. The Multiplexer also switches the
sound Sensors to a loudspeaker on the Operators Panel so that you can listen to any selected
point. When the computer has processed the sounds they are displayed on the Colour Graphic
Display in the form of audio spectrums, alarm bar graphs, mimics and trends. Any of these can
be printed out as hard copy on the dot matrix Printer. The Operators Panel is used by the Plant
Operator to select the various screen displays, control the printout, accept alarm and set time.

3.5 SYSTEM WORKING PRINCIPLE

3.5.1 Audio Pipe work
The sound pressure waves from the combustion chamber are conducted through the steel stub
pipe, the PVC pipe and the Y-piece to the Sensor. The combination of steel Stub Pipe and PVC
extender has a temperature gradient from about 800 Deg C at the boiler wall to about 60 Deg C
at the PVC flange and about 40 Deg C at the Sensor. The pipework is fitted with a cleaning and
rodding valve for routine maintenance purposes. This valve MUST be kept closed during running
or the PVC will melt if the boiler goes positive.

3.5.2 Audio Sensors/Head Amplifiers

The Audio Sensor is a miniature industrial pressure transmitter encapsulated in a sealed acid and
dust-proof capsule. The characteristic is selected to be most sensitive at the tube leak
frequencies. Due to the harsh environmental conditions including high ambient temperatures this
sensor has a limited life. The sensitivity drops off after a period of typically five years at which
stage the sensor capsule can be changed by the station C&I department.

The Head Amplifier is mounted in the cast aluminium Sensor housing and it's function is to
amplify the Sensor signal to a high level suitable for transmission to the Control Room. The C&I
department can adjust the gain to allow for different background sounds or capsule sensitivities.

3.5.3 Multiplexer / Computer

The Multiplexer / Computer is contained in a 19" rack housing situated in the Control Room. All
the field Sensor cables terminate on the back of this housing. The Multiplexer / Computer
contains power supplies to energise the field sensors and electronic switches to select the
sensors in turn to the computer for analysis. An additional selector switches any Sensor required
by the operator on to the Loudspeaker.

The built-in single card computer is a standard industrial computer with additional components to
enable it to compute the FFT and I/O cards to digitise the audio signals. All signals between
computer and field are isolated to improve reliability. The program for running the system is
contained in flash memory. To start up simply switch the multiplexer on. No keyboard is required
with this system.

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 The in-built computer generates audio Spectrums for every Sensor input. The Spectrum is a
graph of sound loudness measured in Decibels (dB) verses Frequency (Hz). This sound pattern,
also known as a Signature, changes in a specific way when a steam leak occurs.

The in-built computer scans every sensor to generate a spectrum and, according to a formula
programmed in from experience, generates an Alarm Bar from each spectrum. The amplitude of
the Bar increases with increasing steam leak sounds. In Bar graph display mode the entire
sensor Alarms Bars are shown on one screen to give an overall view of the boiler condition. The
computer can also create a Mimic display to show the Operator where on the boiler the leak is
taking place.
Trends can be selected for any sensor input to show the alarm condition over the last 32 hours.
3.5.4 Visual Display Unit (VDU)
A standard Colour VGA screen is used to display the various sensor Spectrums, Alarm Bar
graphs, Mimic and Trends.
3.5.5 Printer
The Printer is a standard 80 column dot-matrix type. It is used to record any unusual events or to
print out audio spectrums of all the Sensors at initial commissioning for comparison later.
3.5.6 Operator Panel
The 4-way switch on the operator panel can select the display screens. These screens are:
SPECTRUM, BAR, MIMIC and TREND. Examples of these screens and their descriptions are
given in the colour brochure attached to the INSTRUCTION MANUAL.
Bar graph
ᇏ Vertical co-ordinate is processed ALARM LEVEL in %

ᇏ Horizontal is SENSOR NUMBERS 1 to 32.

ᇏ The system is generally run in BARGRAPH mode, as this displays all sensors
simultaneously.
ᇏ Should there be a tube leak in a certain area of the boiler, a number of bars would
start climbing into the red zone.
ᇏ An examination of which bars were the highest would give an indication of sensors
situated closest to the leak.
ᇏ Each bar should normally be in the green, but the caution area is yellow and danger
is in the red.
ᇏ A blocked wave guide or faulty condition is shown in blue.
Mimic
ᇏ Vertical co-ordinate is BOILER LEVEL (height) in metres...

ᇏ Horizontal is a pictorial display of the boiler layout.

ᇏ The position of the sensors in relation to the boiler are shown and the condition of
each sensor is shown in colour.
ᇏ Microphones are normally numbered sequentially top to bottom odd numbers on the
left/front and even numbers on the right/back.
ᇏ The MIMIC display is selected in order to see the physical location of the leak area on
the boiler.

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Spectrum
ᇏ Vertical co-ordinate is dB, a measure of sound loudness.

ᇏ Horizontal is 313 Hz to 10k Hz, the sound frequency.

ᇏ The audio spectrum of any particular sound sensor can be examined by switching to
SPECTRUM and selecting the appropriate sensor on the two-digit thumb wheel.
ᇏ Background sounds inside the boiler combustion chamber, superheater and
economiser are generally of a low audio frequency, from 50 Hz to 2 kHz.
ᇏ Tube leak sounds are in the 4 to 8 kHz range.

ᇏ Our INSPECTA FFT shows you what the sound looks like whilst the computer runs
an expert analysis on the spectrum to generate the alarm bar.
ᇏ This analysis looks at leak frequencies , ignore low level sounds and includes some
background sounds to detect blocked wave guides.
Trend
ᇏ Vertical co-ordinate is Alarm Level in %

ᇏ Horizontal is Time Past 0 to 31 HOURS.

ᇏ The alarm levels of any particular sensor can be examined over the past 31 hours by
switching to TREND and selecting the appropriate sensor on the two digit thumb
wheel.
ᇏ This trend shows the rate at which the leak has developed.

ᇏ A slow climb over many hours indicates a progressively growing leak which could
level out, allowing for a planned shut-down or a fast growth indicating a pipe burst
which would require immediate action.
Audio
ᇏ Should you wish to listen to the sound from any sensor press the AUDIO push button
and select the required sensor on the two-digit thumb wheel.
ᇏ In order to compare sound levels between different points and also to compare
healthy with steam leak sounds, no volume control is user accessible.
ᇏ When steam leaks or soot blowing occurs the sound is very loud and, for that reason
the AUDIO push button should be switched off by pressing the AUDIO push button
again.
ᇏ Under normal circumstances, a gentle hum or hiss will be heard.

ᇏ Soot blowing or tube leak conditions result in an extremely loud whistling noise.

ᇏ Rotating soot blowers can be identified by the regular rise and fall in sound.
Alarm Accept
ᇏ This push button accepts the alarm and only cancels the audio alarm coming from the
computer.
Print Screen
ᇏ Should you require a PRINTOUT of the screen display at any time, for example
during a suspected tube leak or for recording audio signatures, simply press the
PRINT SCREEN push button.

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 Set Time
ᇏ Date and time setting is altered by using a key to switch to SET TIME.

ᇏ A small continuous display of date and time will appear with a large flashing display of
year, month, day, hour, minute or seconds.
ᇏ The single digit thumb wheel selects the flashing display with 0 = seconds, 1 =
minutes, 2 = hour, 3 = day, 4 = month and 5 = year.
ᇏ The value is altered using the two digit thumb wheel switch.

ᇏ Press PRINT SCREEN to enter.

ᇏ When all dates and times correct on the small display switch back to RUN.

ᇏ The battery backed clock in the computer will now be set.

Automatic Printout
ᇏ Automatic printouts can be achieved by setting the BAR toggle-switch ON for bar
graph printouts and the SPECTRUM toggle-switch ON plus two-digit thumb wheel for
sensor selection for spectrum printouts.
ᇏ The time interval between printouts is selected on the single digit thumb wheel switch
in minutes X 10.
ᇏ When the toggle switch/s is ON and the thumb wheel is on '0' then one automatic
printout takes place each time the system goes into 'Tube Leak Alarm' condition.

3.6 INTERPRETATION OF ALARMS

Besides TUBE LEAKS, various other influences and noises can cause the system to display and activate
an alarm condition. The most common cause is soot blowing. For this reason the INSPECTA FFT
should be mounted next to the soot blowing controls so that the two systems can complement each other.
The soot blowing process tests that the Tube Leak Detection System is functional and the INSPECTA
FFT is used to check that the soot blowers are shut off at the end of their cycle. Many a potential tube
leak has been prevented by detecting faulty soot blowing equipment. The alarm inhibit contact is
specifically fitted for use during soot blowing. During alarm inhibit the alarm bar graph will be grey instead
of red and the alarm relay will remain in “safe” condition.

Other outside influences such as nearby valve packing leaks, compressed air leaks and faulty machinery
close to the sensors can cause false alarm conditions. The causes of these interference’s should be
isolated and corrected.

The INSPECTA FFT is highly sensitive to tube leak frequencies and can often detect a pinhole sized leak.
It can sometimes take days before the leak has developed enough to be heard by the human ear.
Secondary confirmation by hearing the leak is needed before further action is taken.

In view of the above it is extremely important that in the event of a suspected tube leak a full visual and
audio inspection is carried out to determine the exact source and cause of the alarm. Only then should a

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decision be made to take the boiler off line.

3.7 ALARM OUTPUTS AND REMOTE CONTROL

Tube Leak Alarm
ᇏ This is the main alarm and comes on one minute after any sensor has gone into an alarm
condition. (Showing red on the alarm bar).
ᇏ It will reset immediately the alarm condition returns to normal.(See Section 3.5
INTERPRETATION OF ALARMS)
Printer Alarm
ᇏ This alarm is activated if printout is required but printer is not on line or faulty, out of paper, etc.

Low Level
ᇏ When any input signal is below a pre-set value of background sound the alarm display and
mimic number will change to blue.
ᇏ At the same time the low level output relay will be activated.

ᇏ This low level alarm and the blue displays are normally an indication that the listening
pipework is blocked with soot and that routine maintenance is required.
ᇏ If the pipework is cleared of soot and this alarm condition persists then the instrument
technicians should be advised so that they can check the cabling or electronics.

Power Failure
ᇏ This relay is activated when the power is on and drops out when power is off to the Multiplexer
/ Computer, or if the system is not operational.

Inhibit Alarm
ᇏ By externally closing this contact the system will not activate the alarm relay or sound the
internal audible alarm.
ᇏ Screen displays will remain unaffected.

ᇏ This contact should be interlocked with the soot blowing control system.

Alarm Accept
ᇏ This contact only cancels the audio alarm remotely.

ᇏ It is not normally used, as it is also available on the operators control panel.

3.8 ROUTINES
3.8.1 Listening Tubes
ᇏ Routine maintenance is required to remove soot build-up at the mouth of the listening tube.

ᇏ The time it takes varies from boiler to boiler, but is generally from four to six weeks.

ᇏ Our INSPECTA FFT is unique in that it monitors the background sound to determine when the

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 pipework has reached a level of blockage that would affect its performance.
ᇏ At this stage the mimic numbers and alarm bars of the affected sensor change to blue.
3.8.2 Maintenance procedure is as follows:
i. At least once a day, preferably after soot blowing when checking that all displays have
returned to normal, the operator must also check that no sensors are in the blue. If any sensor
points are in the blue the operator must see that the pipework is cleared of soot. This is
achieved by going to the pipework in question and opening the PVC ball valve to allow air to
be sucked into the boiler. Usually one to two minutes is enough. When air flows freely into
the valve it is a sign that the pipework is clear. CAUTION: If the valve is opened and air or
soot blows outwards, immediately close off the valve again, wait a few minutes for the boiler to
go into its normally negative pressure state, then try again. The valve must not be left open
with air coming out or the pipework and/or sensor will be damaged by the heat. Make sure
that the valve is left closed.
ii. If the pipework does not clear by air draught alone then it must be rodded. This normally only
occurs if it has been blocked for a long time allowing condensate to form clinker. For rodding
use a fairly rigid wire. Our technicians use a two meter long electricians fish wire that can be
coiled up and kept in a toolbox.
iii. After clearing the pipework check that the display has returned to green. If not then call in the
Instrument Technicians who will test the system as described in the calibration procedure.

4.1 FIELD CALIBRATION

ᇏ Full system calibration is required at initial commissioning and at half yearly intervals thereafter.

ᇏ Do not recalibrate on a daily or weekly or monthly basis as some leaks develop slowly over this period
and could be hidden by regular recalibration.
ᇏ Remember that leaks make the sound grow whereas sensor failure can only make the sound fade.

ᇏ Sensors can degrade over about five years.

ᇏ If you cannot get the Sensor calibrated when the gain potentiometer is turned up fully replace the
Sensor capsule.
ᇏ If a Sensor is replaced it must be recalibrated.

ᇏ The RR-4 Sound Source is not a calibrator. It is a tool for checking the operation of Sensors, setting
the Sensors to a common pre-calibration gain and used for checking the correct location of Sensors on
the boiler. Final calibration is carried out using the calibration line on the BARGRAPH display which
shows the correct sound level for each Sensor relative to it’s position on the boiler.

4.2 INSPECTA FFT CALIBRATION PROCEDURE

1. The boiler should be running at 75-100% load.

2. A full physical inspection should take place to ensure that every listening pipe (wave-guide) is clear
of fly-ash. All cleaning/rodding valves must be closed (or isolating valves on pressurised boilers open).

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 Check that there are no sounds of any leaks or abnormal noises either inside or outside the boiler near
the sensors that could interfere with the calibration.

3. Power up the INSPECTA FFT system and check that every Sensor is operational and in the correct
location on the Mimic, using the RR-4 SOUND SOURCE. To do this remove the complete
Sensor/head amplifier from the PVC quick release coupling and place it into the RR-4. When the RR-4
is switched on it emits a tone at approximately 4kHz frequency. Using a multimeter set the head
amplifier pre-calibration by trimming the gain potentiometer to give 500mV AC when measured on
the test plugs. Both the gain potentiometer and test plugs are located in the sensor head under the
screw off cap.

4. This 4 kHz signal can be seen on the Spectrum display and will bring the Alarm Bar for that sensor
up into an alarm condition. Using two-way radios for convenience check that the sensors are
connected in the correct physical location on the boiler to correspond with the correct Mimic
position. Remount the Sensor and modify the field wiring if necessary. Repeat for all Sensors.

5. Reboot the system by switching off the power supply for 30 seconds and then back on. When the
INSPECTA-FFT logo appears on the screen press the ALARM ACCEPT push-button. This will
bring up a calibration line at 36% on the BARGRAPH display. Use this display for final
calibration.

6. Start with Sensor No.1 in operating position on the wave guide monitoring the background sound,
ensuring that the cleaning/rodding valve is closed (isolating valve open on pressurised boilers).
Using two-way radios with one person at the Sensor and one in the Control Room adjust the gain
potentiometer until the green bar for No.1 Sensor touches the calibration line.

7. When setting the gain potentiometer make half turn adjustments and then wait for about 30
seconds to see the effect. Note that the sound inside the combustion chamber fluctuates by about
5% so that the average setting should be at the calibration line. Repeat with all other sensors.

8. Calibration is now complete. For record purposes it is advisable to print out the BARGRAPH and
SPECTRUMS of each Sensor. These can be used for comparison purposes if a small leak is detected
in future. Reboot the system to remove the calibration line.

9. Note that the new Test Point values will now be much lower than the original 500mV AC pre-
calibration values from the RR-4

10. Should any repair work take place in the RR-4 sound source it can be set by measuring the voltage
across the piezoelectric sounder with an oscilloscope and adjusting the trim pot to give 2V peak to
peak.

Page 16
4.3 SYSTEM FAULT FINDING PROCEDURE

The following paragraphs list system faults that can be corrected by Sensor or card replacement. All
Sensors and most cards are plug connected for ease of maintenance or fault finding. Card repairs should
be only carried out by the manufacturers or their authorised distributors.

i FAULT: System not on, VDU not on, no LED’s on inside of Multiplexer housing.
CHECK: Power supply to system, on/off switch, fuse.

ii FAULT: System LED’s inside multiplexer housing on, VDU on but not booting up on switch on.
CHECK: CPU card (Plug in) or MUXPSU switch mode power supply which is fused inside cover.

iii FAULT: System boots up to display all screens but alarm BARGRAPH screen shows all bars in
blue (low level)
CHECK: Audio by pressing Audio push-button on Operator panel. If audio is correct replace
MUXMPU card (plug in) or MPUADC (plug in). If no sound on any channel check for
blocked wave-guides (stub pipes), isolating valves closed (on pressurised boiler only).
Using RR-4 sound source check that audio signal is getting to multiplexer, if not check
that the 24 DC power is on all V+ and V- terminals. Check PSUMTR, 24V LED on top of
board should be on the four LED’s on bottom should be on. Replace PSUMTR if faulty.
(The PCB is not plug in).

iv FAULT:One bar on BARGRAPH in blue.

CHECK: Audio by pressing Audio push-button on Operator Panel and selecting that channel. If no
sound check that wave-guide is not blocked. Check that sound is coming through using
RR-4 sound source over Sensor. If not check voltage on V+ and V- in sensor head which
should be 16 to 24 V DC. If no voltage check cables and measure in Junction Box. If
voltage correct check that gain potentiometer has not been turned down (see system
calibration). If still not operational exchange Sensor/head amp complete. If now working,
the Sensor/head amp can be serviced by exchanging the Sensor capsule and checking
that it is operational then recalibrating in position.

v FAULT :Four bars on the BARGRAPH in blue in a group 1-4, 5-8, 9-12, 13-16, 17-20, 21-24, 25-
28 or 29-32.
CHECK:Audio as above. If no sound check wave-guide blockage and use RR-2, then check
voltage on V+ and V-. If no voltage on a group of four listed above it means that a short
circuit is pulling all four voltages down. On the back of the multiplexer housing unplug the
group and check the V+ and V- output from the multiplexer returns to 24 V DC. If not
exchange MUXISO card (plug in). If it does go back to 24 V DC then the multiplexer
power supply is working. Reconnect the plug and disconnect all four Sensors in the
field. If the multiplexer side 24V DC collapses it is a cable fault, if not it is a short in the
Sensor. Reconnect one at a time to check which one and replace.

Page 17
 vi FAULT: System indicates alarm on one channel when no tube leak is present.
CHECK: Listen to the audio sound. Check that the Cleaning / rodding valve is closed. Look and
listen around the Sensor location for any interference sounds or air leaks. Unplug the
Sensor cable and see that the bar on the BARGRAPH display goes to blue, this
indicates that the multiplexer / CPU section is working correctly. Connect another
Sensor / head amp from the opposite side of the boiler sides. If the alarm goes away
then replace the Sensor / head amp and recalibrate. Damaged or loose diaphragms in
the Sensor cause rustling or crackling sounds resulting in false alarms.

vii FAULT: SPECTRUMS and BARGRAPH working but no audio.

CHECK:Audio multiplexer / amplifier card MUXAMP (plug in) or loudspeaker. Cable between
MUXAMP and OP PANEL. Connections between OP PANEL and loudspeaker.

4.4 PRINTER AND CONTROL ROOM EQUIPMENT

ᇏ The printer must be kept clean and filled with an adequate supply of paper.

ᇏ Ribbons should be replaced as required.

ᇏ Consult the printer manufacturer's handbook for maintenance instructions.

5. Document revisions

Ver Description Date

3.3 Converted to star office format 9 Oct 2001
3.4 Better pictures : pipe mounting, screen info 9 Oct 2001
3.5 Serial printer muxbox ver 4 information 5 Nov 2001
3.6 New fonts,pictures and styling 09/07/04

Page 18
Drawing of Flange for mounting PVC Pipeset Assembly

Page 19
Page 20
 INHIBIT TUBE LEAK ALARM IN ZONE

ZONE 2 1 0 DETAILS
C 1 3 4

0 0 0 0 No zone inhibited.
1 0 0 1 Zone 1 inhibited.
2 0 1 0 Zone 2 inhibited.
3 0 1 1 Zone 3 inhibited.
4 1 0 0 Zone 4 inhibited.
5 1 0 1 Zone 5 inhibited.
6 1 1 0 Zone 6 inhibited.
7 1 1 1 All microphones inhibited.

Page 21
SAFETY

Power supplies to the multiplexor housing are from the mains supply, 110
or 220v AC, and should only be handled by qualified electrical personnel.
Covers on the above equipment should not be removed whilst power is
connected.

All field wiring is low voltage isolated DC and designed to be short circuit
resistant. It can be handled with complete safety.

WARNING

CLOSE THE ISOLATING VALVE BEFORE DOING ANY WORK ON THE PIPE
SET OR MICROPHONE.

IF YOU LEAVE THE VALVE OPEN THE PIPE AND MICROPHONE WILL BE
DAMAGED BY HOT AIR FLOW FROM THE BOILER PRESSURE, IN CASE
OF BEING POSSIBLE.

When carrying out clearing of the sensor stub pipes (the procedure is
given in routines) care must taken to stand to one side when opening the
cleaning cap as the boiler pressure is positive. In this instance hot air
could blow out the pipe resulting in injury.
Safety symbols

* The symbol is affixed to locations on the equipment where the

operator should consult corresponding topics in this manual
(which are also marked with the symbol) before using
Relevant functions of the equipment.
* In the manual, this mark indicates explanations which it is
particularly important that the user read before using the
equipment

This symbol denoted the ground terminal

~ This symbol means alternating current (AC)

This symbol denotes a fuse

WARNING Indicates that incorrect operation presents significant danger of

Accident resulting in death or serious injury to the user.

Indicates that incorrect operation presents possibility of injury

CAUTION to the user or damage to the equipment

Denotes items of advice related to performance of the

NOTE
Equipment or to its correct operation.
 Appendix : Air Purge
i) General

To reduce maintenance requirements an automatic air purge system can be

used.

This system clears the listening tubes of dust from time to time.

ii) Installation

The kit consists of the following :

PVC saddle + Solenoid + Fitting + Plug

Fit the PVC saddle over the hole on the FFT-PVC pipe set.
Ensure that there is an o ring between the saddle and the pvc pipe.
Plug the hose into the quick release fitting on the solenoid.
Plug the hose into the air supply gate valve.
Turn on the air supply.
Wire the 24Vdc supply to the DIN plug pin 1 and 2.

v) Note

When the solenoid releases air it creates a loud sound.

This sound is picked up by the system as a tube leak.
The system will only generate an alarm if the sound persists for one minute.
ie. If a solenoid is leaking or stuck it will generate an alarm.
BAR GRAPH (Default Screen)

FFTSmanu.pdf Page 1 of 10
MIMIC SCREEN

FFT SCADA pictures Page 2 of 10

 BOILER TREND (CHARTS)

Double right click to expand a TREND chart, as shown below:

FFT SCADA pictures Page 3 of 10

SPECTRUM ANALYSIS

FFT SCADA pictures Page 4 of 10

 LOGGED DATA

Alarm TABLE

FFT SCADA pictures Page 5 of 10

Boiler 1 Log TABLE

FFT SCADA pictures Page 6 of 10

REVIEW PROGRAM

FFT SCADA pictures Page 7 of 10

 TREND REVIEW

Double right click to expand a TREND chart, as shown below:

FFT SCADA pictures Page 8 of 10

SPECTRUM REVIEW

FFT SCADA pictures Page 9 of 10

MIMIC REVIEW

FFT SCADA pictures Page 10 of 10



 
* # * # * # * #
S1 S1 S1 S1
SV1 SV1 SV1 SV1
S2 S2 S2 S2
SV2 SV2 SV2 SV2
S3 S3 S3 S3
SV3 SV3 SV3 SV3
S4 S4 S4 S4
SV4 SV4 SV4 SV4
S5 S5 S5 S5
SV5 SV5 SV5 SV5
S6 S6 S6 S6
SV6 SV6 SV6 SV6
LEGEND:
NOTE: COLOR CODING CABLE WILL BE
V+ +24 V TO SIGNAL
FOR 4 PAIR RED + BLUE,
V- 0V YELLOW+GRAY,GREEN + BROWN,
C SIGNAL COMMON WHITE + BLACK. FOR 12 PAIR
SAME AS ABOVE COLOR OF
S SENSOR SIGNAL
3 UNITS WITH BAND MARKING
SV+ 24+ POWER SUPPLY TO
SOLENOID VALVE
SV- 0V
0.5 Sq mm 4 TWISTED PAIR "F" TYPE
* CABLE

# 0.5 Sq mm 12 TWISTED PAIR

"F"TYPE CABLE
 TO SENSOR

* C1(4 PAIR)
# V+
C1P1 B1P1
S1 V-
C1
C1P2 B1P2
S1
SV+
SV1 C1P3 B3P1
SV-

C2(4 PAIR)
C2P1
S2 C2P2 B2P2 C2
S2

SV2 C2P3

C3(4 PAIR)
C3P1
S3 C3P2 B3P2
C3
S3

SV3 C3P3

C4(4 PAIR)
C4P1
S4 C4P2 B1P3
C4
S4

SV4 C4P3

C5(4 PAIR)
C5P1 B2P1 V+
V-
S5 C5P2 C5
B2P3
S5

SV5 C5P3

C6(4 PAIR)
C6P1
S6 C6
C6P2 B3P3 S6
SV6 C6P3

LEGEND
B1(BAND 1)-4 PAIR B2(BAND 2)-4 PAIR B3(BAND 3)-4 PAIR

PAIR 1 RED + BLUE (P1) RED + BLUE (P1) RED + BLUE (P1)
PAIR 2 YELLOW + GREY (P2) YELLOW + GREY (P2) YELLOW + GREY (P2)
PAIR 3 GREEN + BROWN (P3) GREEN + BROWN (P3) GREEN + BROWN (P3)
PAIR 4 WHITE + BLACK (P4) WHITE + BLACK (P4) WHITE + BLACK (P4)

B1 P4, B2 P4 & B3 P4 - SPARE PAIRS

 TO SENSOR

* C1(4 PAIR)
# V+
C1P1 B1P1
S1 V-
C1
C1P2 B1P2
S1
SV+
SV1 C1P3 B3P1
SV-

C2(4 PAIR)
C2P1
S2 C2P2 B2P2 C2
S2
SV2 C2P3

C3(4 PAIR)
C3P1
S3 C3P2 B3P2
C3
S3

SV3 C3P3

C4(4 PAIR)
C4P1
S4 C4P2 B1P3
C4
S4

SV4 C4P3

C5(4 PAIR)
C5P1 B2P1 V+
V-
S5 C5P2 B2P3 C5
S5

SV5 C5P3

C6(4 PAIR)
C6P1
S6 C6
C6P2 B3P3 S6

SV6 C6P3

LEGEND
B1(BAND 1)-4 PAIR B2(BAND 2)-4 PAIR B3(BAND 3)-4 PAIR

PAIR 1 RED + BLUE (P1) RED + BLUE (P1) RED + BLUE (P1)
PAIR 2 YELLOW + GREY (P2) YELLOW + GREY (P2) YELLOW + GREY (P2)
PAIR 3 GREEN + BROWN (P3) GREEN + BROWN (P3) GREEN + BROWN (P3)
PAIR 4 WHITE + BLACK (P4) WHITE + BLACK (P4) WHITE + BLACK (P4)

B1 P4, B2 P4 & B3 P4 - SPARE PAIRS

 TO SENSOR

* C1(4 PAIR)
# V+
C1P1 B1P1
S1 V-
C1
C1P2 B1P2
S1
SV+
SV1 C1P3 B3P1
SV-

C2(4 PAIR)
C2P1
S2 C2P2 C2
B2P2
S2

SV2 C2P3

C3(4 PAIR)
C3P1
S3 C3P2 B3P2
C3
S3

SV3 C3P3

C4(4 PAIR)
C4P1
S4 B1P3
C4
C4P2
S4

SV4 C4P3

C5(4 PAIR)
C5P1 B2P1 V+
V-
S5 C5P2 C5
B2P3
S5

SV5 C5P3

C6(4 PAIR)
C6P1
S6 C6
C6P2 B3P3 S6

SV6 C6P3

LEGEND
B1(BAND 1)-4 PAIR B2(BAND 2)-4 PAIR B3(BAND 3)-4 PAIR

PAIR 1 RED + BLUE (P1) RED + BLUE (P1) RED + BLUE (P1)
PAIR 2 YELLOW + GREY (P2) YELLOW + GREY (P2) YELLOW + GREY (P2)
PAIR 3 GREEN + BROWN (P3) GREEN + BROWN (P3) GREEN + BROWN (P3)
PAIR 4 WHITE + BLACK (P4) WHITE + BLACK (P4) WHITE + BLACK (P4)

B1 P4, B2 P4 & B3 P4 - SPARE PAIRS

 TO SENSOR

* C1(4 PAIR)
# V+
C1P1 B1P1
S1 V-
C1
C1P2 B1P2
S1
SV+
SV1 C1P3 B3P1
SV-

C2(4 PAIR)
C2P1
S2 C2P2 B2P2 C2
S2

SV2 C2P3

C3(4 PAIR)
C3P1
S3 C3P2 B3P2
C3
S3

SV3 C3P3

C4(4 PAIR)
C4P1
S4 B1P3
C4
C4P2
S4

SV4 C4P3

C5(4 PAIR)
C5P1 B2P1 V+
V-
S5 C5P2 C5
B2P3
S5

SV5 C5P3

C6(4 PAIR)
C6P1
S6 C6
C6P2 B3P3 S6

SV6 C6P3

LEGEND
B1(BAND 1)-4 PAIR B2(BAND 2)-4 PAIR B3(BAND 3)-4 PAIR

PAIR 1 RED + BLUE (P1) RED + BLUE (P1) RED + BLUE (P1)
PAIR 2 YELLOW + GREY (P2) YELLOW + GREY (P2) YELLOW + GREY (P2)
PAIR 3 GREEN + BROWN (P3) GREEN + BROWN (P3) GREEN + BROWN (P3)
PAIR 4 WHITE + BLACK (P4) WHITE + BLACK (P4) WHITE + BLACK (P4)

B1 P4, B2 P4 & B3 P4 - SPARE PAIRS

800
2100mm

2100mm

INSTROTECH (PTY) LTD

SOUTH AFRICA