DEVELOPMENT OF A SYSTEM FOR

DETECTION OF BLOCKAGE IN
PIPES & TUBES

N Dhanasekaran, WRI
S S Ananthan , WRI
S V Srinivasan, IPP
 OBJECTIVE

To develop a system for detecting and

locating blockage in tubes and pipes in
steam generator components and heat
exchanger components in utility and
Industrial power plants
 DEVELOPMENT OF A SYSTEM FOR
DETECTION OF BLOCKAGE IN PIPES &
TUBES

[7 – 379 – 115 - 299 ]

Duration : June 2002 – Dec 2003

Project Outlay: Rs. 29.0 Lakhs
Expected date of completion : June 2004
[The equipment expected by March 2004]
ACTIVITIES COMPLETED
SM/FES WITNESSED DEMO OF TUBE
BLOCKAGE SYSTEM IN UK
P.O.PLACED FOR TUBE BLOCKAGE DETECTOR
SYSTEM EXPECTED IN FIRST WEEK OF
MARCH 2004
REMOTE VISUAL INSPECTION TOOL
RECEIVED AND COMMISIONNED
DESIGN FOR LOCATOR IN HEADER FROZEN
STATUS
EXPECTED DATE OF COMPLETION
JUNE 2004
Thank you
PRINCIPLE OF OPERATION
Audible pulse propagated through air in
tube or pipe
Reflections occur at discontinuities –
Holes, Kinks and Changes in section
Returning echoes detected by
microphone
TOTAL SYSTEM
 TEST SETUP
Sensor Tube

Display
Pulser unit
TYPICAL INDICATION
TYPICAL INDICATION
TYPICAL INDICATION
Proposed Locator for Header

Acoustic guide
Nipple
/Header

Nipple
locator

Sensor

Viewing
system
ANTICIPATED BENEFITS
Reduces the downtime in plants during
analysis of blockages
Increased customer confidence and field
personnel when such failure occurs
Can be made a mandatory check for
confirming the absence of tube
blockages in the suspected power
stations
Proposed Applications
During shut down for locating the
blockages in tubes
Can be used in the shop production for
identifying any foreign objects in the
tube bends etc wherever suspected
Can be used during erection before final
welding to locate any foreign objects in
tubes and pipes
MAJOR ACTIVITIES COMPLETED
Procurement action initiated for remote
viewing system, tube blockage system. In
the advanced stage of procurement.
Literature collected for tube blockage
system
Conceptual design completed for the
locating system
Artificial blockage specimens under
preparation
BACKGROUND
Tube blockages in water walls and heat
exchangers lead to outage of the system
The blockage can be detected only after
failure occurs
If failure occurs in one tube there is no
method to confirm blockage in the next
tube and the suspected tubes
RT may be taken in only suspected
areas. Entire Length cannot be checked
SCOPE OF PROJECT
Procure the tube blockage
detection system
Conduct trials with artificial
defects and blockages
Calibrate the system
Establish the methodology with
pipes in shops
Develop a locator for headers