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Abstract
1. INTRODUCTION
Innovations of the conventional methods of day to day methods of maintenance activities
have resulted in the saving of both time and labour. But Thermal Power Stations in India are
suffering from certain long term problems whose remedies are still in the future prospects of
R&D activities. The challenges faced during the day to day operation and maintenance
activities at the Thermal Power Stations affects adversely the National Economy and thereby
endangering the countrys population into a dark future of Power Failure. However, the
immediate technical remedy to this problem of Boiler Tube Failure has emphasized the
concept of Condition Monitoring activities. Again, very specifically stating any noninvasive
techniques utilized to determine the integrity of a material, component or structure or
quantitatively measure some characteristic of an object i.e. measure without doing any harm
can be considered as Non Destructive Examination. It is definitely for this reason Non
Destructive Testing has occupied a vast region both in the industrial as well as in the R&D
sector. Every year Thermal Power Stations under renowned PSU sectors spend several lacs
for the Condition monitoring operations among which a handful of operations can be
considered as Non Destructive Techniques. The concept of this paper is to highlight the
several Non Destructive Testing practices at the Thermal Power Stations and thereby
emphasizing upon the professional skills and dedications of innumerable field engineers,
technicians and scientists for successful implementation of these techniques during the
present period of National Crisis in Power Generation.
1.1 Wall Thickness Measurement and Scale Detection using Ultrasonic Techniques:
Scale deposition inside the Boiler Tubes is a region of perennial worry at the Power Stations.
A handful of Boiler Tube Failure cases can be attributed to Scale Deposition. The scales are
mostly composed of Iron oxides and in some cases CaCO3 and certain other compounds
depending upon chemical reactions and the nature of water. Purification of river water by
using some chemical compounds is a burning issue of research interest in Analytical
Chemistry but Scale detection and Wall thickness measurement using Ultrasonic Techniques
has proved to be an immediate remedial measure to this long term problem. A tube with scale
deposition of more than 30-32 microns can be considered as failed tube. Accurate scale
detection and Wall Thickness Measurement not only predicts the tube condition but also
guides the Acid Cleaning procedure so that the tube can be saved before being discarded.
Consists of an electronic signal generating device that produce the alternating voltage, a
transducer or probe that emits a beam of Ultrasonic Wave when alternating voltage is applied
to it and recieves the corresponding waves from the test piece, a couplant to act as a medium
between the test piece and the transducer, An electronic device to amplify, demodul;ate or
modify the signal from the transducer, a dispaly device to demonstrate the trhickness reading,
An electronic clock or timer to control the sequence of operations. In this case the Ultrasonic
Unit calculates the distance from the known Time and Velocity of Sound Wave. The Velocity
of sound differs in different metals and has to be set by the operator. In certain cases, the
instrument itself sets it. The total distance travelled by the ultrasonic pulses, is obtained by
the distance from the initial pulse or front surface to the back reflection from the back
surface.
2)
Its operating temperature of -4 degreeF to 115 degreeF & storage temperature of 13degreeF to 140 degreeF make this fully compatible for utilization at thermal
power stations.
All Way articulation of the camera fitted at the top of its probe makes it possible
to reach at those places which cannot be accessed by the naked eyes.
Mainly those locations that cannot be reached b the naked eye comes under its areas of
operations. This includes the diaphragms of turbines during the short time overhauling, the
internal surfaces of tubes of any locations, boiler hadders etc. It provides a sharp magnified
image that can detect cracks or any type of surface deposition thereby visualizing surface
topography. Rapid rate of inspection as a part of regular maintenance can be frequently
conducted by the field engineers without disturbing much the turbine assemblies at regular
intervals which will act as a preventive measure against serious damage & thereby saving
time and labour, hence reducing the frequency and duration of short term overhauling
duration.
Light weight, ergonomic & rugged design, hermetic housing make this instrument
fully portable & user friendly for operations at the power stations.
Non contact velocity measurements can be conducted in the frequency range 0 to
22 KHz, from a distance of .2-30m. The working He-Ne Laser is also eye safe.
Fe2O3, Fe3O4, CaCo3 etc. Mainly in house Testing is carried out and the tube samples have
to be sent from the Power Stations to the concerned testing authority.