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Leak Detection With Thermography & Ultrasonic Acoustics
Leak Detection With Thermography & Ultrasonic Acoustics
Thermography
&
Ultrasonic Acoustics
Presented by:
Matthew Crockett, Engineer
Plant Engineering Programs
Background
Detecting leaking fluids, whether it be steam,
water or different types of gases, is of major
concern at AEP power plants. These leaking
fluids can affect safety, operation, maintenance,
heat rate, and work performance. Detecting leaks
can be difficult in a power plant environment.
AEP has discovered that the combined application
of Infrared Thermography and Ultrasonic
Acoustics as part of a plant Predictive
Maintenance Program can efficiently identify
leaks in many areas.
Infrared Thermography
Infrared Thermography (IR) can be used to detect
leaks on the following equipment/systems :
1.
2.
3.
4.
5.
6.
Valve leakage
396.0F
AR01: >364.3F
66.5F
Valve leakage
Valves and lines going to the condenser,
boiler blowdown, miscellaneous drain tank,
reclaim tank, drip receiver, and priming for
pumps under vacuum should be checked.
All boiler, turbine, stop valve, valve chest,
etc., drain lines need to be checked for leak
through.
DO NOT over tighten valves!
Valve leakage
488.6F
400
300
200
SP01: 393.3F
100
93.7F
Leaking drain
AR01: *598.0F
667.2F
600
500
SP01: 533.9F
400
300
200
176.6F
Steam Traps
361.0F
350
SP01
250
200
150
118.6F
103.2F
100
95
SP01
90
85
80.2F
AR01: 100.8F
110
105
AR02: 103.1F
100.9F
Leaking condenser
expansion joint.
120
100
85.5F
180
160
SP01: 153.4F
140
120
SP02: 173.9F
67 C
o
100
79oC
80
75.8F
Heaters
Heaters can also be checked with IR to
identify heat rate loss items.
Shell safety valves, vents, drains, and
pumps are items to check during a survey.
Both high pressure and low pressure heaters
should be scanned.
Vacuum pumps, LP drain pumps, and other
types should be checked.
Heaters
186.4F
180
160
SP01: *156.6F
140
120
100
93.1F
Safety Valves
All safety valves should be scanned.
Especially those that do not vent to
atmosphere. Those that vent to reclaim or
miscellaneous drain tanks are often
overlooked. High energy piping safeties are
usually reset during outages and vent to
atmosphere.
Boiler
Infrared is very effective when used to identify
boiler and ductwork casing leaks.
Boiler casing leaks increase auxiliary power
use by increasing load on fans and pulverizers.
Reducing casing leaks improves combustion
and reduces excess air.
Total air flow is often reduced (especially on
balance draft units) which decreases emissions
since precipitators, SCRs and FGDs treat less
exit gas.
Boiler
SP01
Ultrasonic Acoustics
Ultrasonic Acoustics
Ultrasonic Acoustics requires skilled personnel with
the proper training.
When used to detect piping leaks it can be effective to
pin point small sources.
Large leaks and background noise can overwhelm
many detectors and require continual adjustments to
find the source. Ultrasonic Acoustic requires turbulent
flow between low and high pressure sources.
Vacuum leaks sound different than pressure leaks and
an experienced user can differentiate between the two.
Shielding of the detector is a useful tool to eliminate
background noise.
Ultrasonic Acoustics
Ultrasonic Acoustics
Example of a
Good Valve
Test Point A = 50 db
Test Point B = 40 db
Test Point C = 17 db
Test Point D = 8 db
Ultrasonic Acoustics
Steam leak
Steam Trap
Performing A Survey
To perform an accurate and effective Infrared
Thermography or Ultrasonic Acoustic survey takes
training on the equipment, planning of what is to be
surveyed, a method of progression, and a knowledge of
the systems involved.
If not trained in the use of this equipment then seek
assistance.
Performing A Survey
Questions prior to a survey
1.
2.
3.
4.
5.
6.
7.
8.
Scope of survey?
Do you have safe access to perform the inspection and what
Personal Protection Equipment is needed?
Does the equipment/systems need to be placed in service? What
other conditions need to be met?
Is the equipment operating such to give meaningful results?
Will it be cost effective to perform the inspection?
Will you be needing additional resources to perform the
inspection?
Can you take advantages of other technologies or procedures to
supplement the findings of the inspection?
When are the results needed/expected?
Analysis
Analysis should be done in a systematic
repeatable format.
Determine the baseline or other industry
accepted standards.
Document source of acceptance criteria.
Problems or anomalies should be reviewed
for determination as to what corrective
actions, if any is required.
Problems should be itemized and prioritized
according to severity, cost, location or other
process specific criteria.
Reporting
Accurate reporting should include the following:
1. Cover Letter/Executive Summary
2. Spread sheet of events sorted according to severity
3. Time/Date/Unit Conditions
4. Equipment identification
5. Location/Diagram
6. Specific problem details with priority
7. Corrective action recommended (if any)
8. Problem action criteria (Severity)
9. Visible Photograph/IR Image/Ultrasound Plot
10. Inspectors Name
Training/Experience
The quality of a Thermography or Ultrasonic Acoustic survey
depends upon training and experience.
Only trained individuals should perform these surveys.
Training can be In-house or vendor supplied.
Apprenticeship type training is highly recommended and
provides the best experience development.
Experience allows for more accurate assigning of severity based
upon component history, or system conditions that differ from
the guidelines provided.
Experience should be communicated through proper reporting.
Experience allows one to improve on techniques.
Trade information and Users Groups are a good source of
experience.
Summary
Infrared Thermography and Ultrasonic Acoustics
both provide accurate detection of fluid leaks
that commonly occur at a power plant.
When combined, the effectiveness of these leak
detection methods increases dramatically.
Confirming a suspected leak detected with one
technology by repeating the detection with a
separate technology is always a best practice.
Proper reporting of findings is key to the
successful application of these technologies.
Questions?