US20070169721A1 - Monitoring a degradation of steam generator boiler tubes - Google Patents

Monitoring a degradation of steam generator boiler tubes Download PDF

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Publication number
US20070169721A1
US20070169721A1 US11/655,085 US65508507A US2007169721A1 US 20070169721 A1 US20070169721 A1 US 20070169721A1 US 65508507 A US65508507 A US 65508507A US 2007169721 A1 US2007169721 A1 US 2007169721A1
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United States
Prior art keywords
degradation
flue gas
boiler tubes
gas tract
combustion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/655,085
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English (en)
Inventor
Wolfgang Weisenstein
Raiko Milanovic
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ABB Technology AG
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ABB Technology AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Technology AG filed Critical ABB Technology AG
Assigned to ABB TECHNOLOGY AG reassignment ABB TECHNOLOGY AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MILANOVIC, RAIKO, WEISENSTEIN, WOLFGANG
Publication of US20070169721A1 publication Critical patent/US20070169721A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/50—Control or safety arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B35/00—Control systems for steam boilers
    • F22B35/007—Control systems for waste heat boilers
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/07—Analysing solids by measuring propagation velocity or propagation time of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/223—Supports, positioning or alignment in fixed situation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/02—Indexing codes associated with the analysed material
    • G01N2291/025—Change of phase or condition
    • G01N2291/0258—Structural degradation, e.g. fatigue of composites, ageing of oils
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/04—Wave modes and trajectories
    • G01N2291/044—Internal reflections (echoes), e.g. on walls or defects
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/04—Wave modes and trajectories
    • G01N2291/048—Transmission, i.e. analysed material between transmitter and receiver
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/263—Surfaces
    • G01N2291/2634—Surfaces cylindrical from outside
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/263—Surfaces
    • G01N2291/2636—Surfaces cylindrical from inside

Definitions

  • the disclosure relates to the operation of large combustion facilities, and more particularly to the monitoring of a degradation of the boiler tubes of the facilities' steam generators.
  • the most significant control parameters defining an operation or combustion mode in waste incineration plants are the mass flows of primary and secondary combustion air, the air temperature, the amount of returned flue gas, the amount of waste or fuel fed and the transportation speed or the stoking speed of a reciprocating grate.
  • An adaptation of these parameters typically occurs on a time scale of days or weeks, and may result in a different position of the flame on the grate and thus to a different flow regime and temperature distribution of the flue gases in the furnace or funnel, i.e. the space above the grate.
  • the plant operating companies can only use periodic downtimes to measure the actual wall thickness of the boiler tubes and to compare the results with results from earlier measurements.
  • the recording and processing of measurements over a long period of time can nevertheless reveal a decrease tendency, which can be used to prepare appropriate maintenance activity. Since such downtimes are scheduled at most twice a year, inspections can usually be performed at best every six months, and a direct correlation of the degradation due to corrosion and/or caking and the abovementioned operation or combustion mode of the plant is impractical.
  • An on-line degradation monitoring for boiler tubes is introduced, which allows determining the degradation or deterioration in a more or less continuous manner while the combustion facility is operating.
  • the degradation evaluation is thus not restricted to optical inspection during downtimes, and a rate or accumulated degradation can be related to past or present operation modes of the facility.
  • Appropriate devices and measurement techniques are provided for introducing and receiving measurement signals into and from a space or volume within a flue gas tract where the boiler tubes are located and exposed to the destructive effects of the flue gases from the combustion process. Hence, environmental conditions are inspected right where they are affecting the boiler tubes.
  • appropriate degradation sensors such as ultrasonic transducers are arranged outside of the flue gas channel guiding the destructive flue gases, and are themselves not exposed to the corrosive atmosphere.
  • an ultrasonic measurement technique is employed for inspecting the degradation of a boiler tube, taking advantage of the fact that both corrosion and caking relate to a build-up of additional interfaces or layers of different composition both reflecting incoming sound waves.
  • Ultrasonic measurement is advantageous as compared to electrical measurements which rely on the fact that the corrosion relates to a changing geometry that can be accessed by determining a change in an electrical resistance. The latter requires extensive numerical correction of the measured resistance to account for the influence of the temperature, and does not allow detecting non-conductive surface deposits. Ultrasonic measurement is not impeded by such constraints.
  • Ultrasonic flaw detection is a standard non-destructive-testing technique used in various industries for quality testing of flaws such as defective welding joints, cast inclusions and contraction cavities in bulk casts. This technology can be adapted for monitoring of the corrosion condition of boiler tubes.
  • a test tube preferably made of a single piece of metal without any welding joint is provided such that it extends into the space or volume within the flue gas tract where the boiler tubes are located.
  • the test tube has no process relevance and is used just for the monitoring of the degradation progress and is advantageously mounted at a position in the flue gas tract where it is exposed to the same or even higher corrosive threats as the boiler tubes, i.e. upstream of the latter, close to the combustion zone.
  • FIG. 1 the main components of a waste incineration plant
  • FIG. 2 a test tube with two dual element ultrasound transducers operating in a through transmission mode
  • FIG. 3 differing echo times as measured by two contact transducers operating in a pulse/echo mode configuration
  • FIG. 4 a single ultrasonic transducer with a waveguide.
  • Industrial ultrasonic flaw detection generally utilizes frequencies between 500 kHz and 10 MHz and is a very common non-destructive material testing method.
  • the propagation of sound waves through solid materials is used to detect hidden cracks, voids, porosity, and any other internal discontinuities in metals, plastics and ceramics.
  • highly directional sound energy travelling through a material encounters a boundary with another material, a portion of the energy will be reflected back and a portion will be transmitted through.
  • high frequency sound waves reflect from grain boundaries and flaws in predictable ways, producing distinctive echo patterns that can be displayed and recorded.
  • Ultrasonic testing is completely non-destructive and safe, and it is a well established test method in many manufacturing and process industries.
  • Typical transducers for industrial ultrasonic applications utilize an active element made of a piezoelectric ceramic, composite or polymer. When this element is excited by a high voltage electrical pulse, it vibrates across a specific spectrum of frequencies and generates a burst of sound waves. Conversely, when excited by an incoming sound wave, it generates an electrical pulse. Because sound energy at ultrasonic frequencies does not travel efficiently through gasses, a thin layer of coupling liquid or gel is usually used between the transducer and the test piece. Contact transducers are used in direct contact with the test piece. They introduce sound energy perpendicular to the surface, and are typically used for locating voids, porosities and cracks.
  • Dual element transducers utilize separate transmitter and receiver elements in a single assembly and perform testing in a continuous pulse-echo mode. Another technique is termed through-transmission, where sound energy travels between the two transducer elements placed on opposite sides of the specimen. Pulse amplitude, shape, and damping can be controlled to optimize transducer performance, and receiver gain and bandwidth can be adjusted to optimize signal-to-noise ratios.
  • FIG. 1 schematically shows a waste incineration plant with the following basic components.
  • An input feed mechanism or actuator 10 introduces the municipal or industrial waste, garbage or other debris into a furnace 11 and places the former on a supported movable grate 12 , thereby forming a waste bed.
  • the grate 12 generally comprises some oppositely moving grate plates to spread and mix the waste and forward it along the grate 12 .
  • Auxiliary burners 13 may be provided in order to start or support the combustion processes.
  • the combusted flue gases are collected in a flue gas tract or flue gas channel 14 upstream of the furnace 11 and guided to a boiler or steam generator 15 .
  • the waste incineration plant is further equipped with an appropriate set of degradation sensors 4 for detecting the progress of the degradation of the boiler 15 .
  • the measured data are processed online in a plant optimization software as part of a plant control system 5 .
  • the incineration process is divided into four zones to be serially traversed by the waste: Drying zone 20 , first combustion zone for pyrolysis and gasification/volatilization 21 , residual zone for char oxidation or solid combustion 22 , and ash treatment/sintering zone 23 . These zones are actually not very well separated in the furnace and can overlap to a certain extent.
  • a second combustion zone or flame zone 24 where the homogeneous gas phase combustion of the pyrolysis gases takes place, is identified above the waste bed.
  • Primary air 30 is fed from below the grate in generally different amounts to the four abovementioned zones 20 , 21 , 22 , 23 .
  • Secondary air 31 is fed above the grate to ensure complete combustion of the gasification and pyrolysis products in the second combustion zone 24 . Due to the extreme environmental conditions in and above the second combustion zone 24 , it is preferable to locate the sensors 4 not in the furnace itself, but rather at the exterior of the flue gas tract 14 .
  • FIG. 2 shows a longitudinal cross-section of a test tube 40 arranged in a flue gas tract 14 and surrounded by boiler tubes 15 a , 15 b oriented perpendicularly to the test tube.
  • the test tube has no process relevance and is used exclusively for the monitoring of the degradation progress.
  • the test tube has to be made of the same material as the boiler tubes, whereas its geometry, e.g. cross section (circular, elliptical, square) may be different from the one of the boiler tubes.
  • a flow of feed water through the test tube is maintained. This feed water is preferably taken from an independent water cycle that can be operated separately from the water/steam cycle flowing through the boiler.
  • test tube is mounted at a position in the flue gas tract where it is exposed to the same or even higher corrosive conditions as the boiler tubes. This ensures that the corrosion of the test tube is always comparable to the corrosion of the boiler tubes, wherein in the worst case the test tube will be the first to fail.
  • the ultrasonic transducer elements or measurement heads 41 a , 41 b , 41 c and 41 d are mounted to annular end planes of the test tube 40 . To avoid thermal damage of the electronic equipment and to ensure reliable operation, the elements are mounted at a certain distance to the boiler and the flue gas tract 14 .
  • the separate transmitter elements 41 a , 41 b and receiver elements 41 c , 41 d form two dual element transducers operating in a through transmission mode and controlled by ultrasonic controller 42 .
  • the latter comprises a wave/pulse generator, an amplifier and an oscilloscope or other device suitable for ultrasound detection and processing.
  • the signal intensity at the receiver elements can be processed to detect the increase of corrosion damages.
  • the decrease of the intensity of the signal depends on a variety of factors, among which the geometric shape of the test tube is directly affected by the degradation effects that the present invention is attempting to identify.
  • FIG. 3 depicts an alternative embodiment with two contact transducers 41 a , 41 b operating in a pulse/echo mode.
  • Ultrasonic testing basically being a comparative technique or relying on proper calibration, the most information can be derived from a comparison of two distinct ultrasound transmission times t a , t b . If, as in FIG. 3 , t b > t a as measured by the two transducers, this implies the existence of an additional sound reflective boundary encountered by the wave originating from and detected by transducer 41 a . As depicted in the first drawing of FIG. 3 , such a boundary may be due to a local, i.e.
  • ultrasound propagation may comprise multiple reflections in the test tube as depicted in the second picture of FIG. 3 , without impairing the usefulness of the procedure, but potentially requiring additional signal processing.
  • a caking effect in the form of a deposit on the surface of the boiler tube clearly affects the ultrasound transmission time t a or gives rise to additional reflections.
  • the two transducers 41 a , 41 b could also be attached to two distinct tubes.
  • a single transducer element would have to rely on the occurrence of two different echoes resulting from a single burst of sound waves, i.e. an acoustically significant echo preceding an echo from the opposite end plane of the tube.
  • FIG. 4 depicts an alternative way of mounting the ultrasonic measurement device 41 a outside of the flue gas tract 14 at a distance from the hot area by means of a wave guide 43 .
  • This solution is advantageous if the most probable location of the corrosion can be identified in advance, e.g. by Computational Fluid Dynamics (CFD) simulation.
  • the remote end of the wave guide is then placed right next to this location for an exclusive monitoring of the local wall thickness at the corresponding corrosion endangered spot using the pulse/echo principle.
  • a broadband ultrasonic wave is initiated by a laser pulse on a surface exciting a mechanical, i.e. acoustic, wave in the material.
  • the wave propagates through the material until encountering a boundary.
  • the reflected wave will cause a minute surface motion (“ripples”) that are picked up by the laser, now operating in reception mode.
  • the unaltered specimen will exhibit a distinctive wave pattern that is compared by interferometry to the latest measurement.
  • An optimization software which correlates the signal modulation of the corrosion monitoring with the parameters of the different operation modes of the plant, allows to create and activate operation modes that reduce boiler corrosion as well as caking and soot deposition to a minimum.
  • maintenance intervals can be adjusted to the actual condition of the plant, undesired downtimes can be avoided and the economic efficiency of the plant can be increased.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Biochemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Pathology (AREA)
  • General Health & Medical Sciences (AREA)
  • Immunology (AREA)
  • Combustion & Propulsion (AREA)
  • Thermal Sciences (AREA)
  • Acoustics & Sound (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)
US11/655,085 2006-01-20 2007-01-19 Monitoring a degradation of steam generator boiler tubes Abandoned US20070169721A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP06405019.8 2006-01-20
EP06405019A EP1811282A1 (en) 2006-01-20 2006-01-20 Monitoring a degradation of steam generator boiler tubes

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EP (1) EP1811282A1 (ja)
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CN (1) CN101004259A (ja)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110087517A1 (en) * 2009-10-12 2011-04-14 Abbott Patrick D Targeted Equipment Monitoring System and Method for Optimizing Equipment Reliability
EP2847584A1 (de) 2012-05-11 2015-03-18 Basf Se Verfahren zur erfassung von schädigungen an einer hohlwelle
US9212569B2 (en) 2010-10-19 2015-12-15 General Electric Company Systems, methods, and apparatus for determining online stress and life consumption of a heat recovery steam generator
US9279346B2 (en) 2010-10-19 2016-03-08 General Electric Company Systems, methods, and apparatus for determining online stress and life consumption of a heat recovery steam generator
WO2022005456A1 (en) * 2020-06-30 2022-01-06 Paneratech, Inc. Antenna-grating sensing system

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JP2012181069A (ja) 2011-02-28 2012-09-20 Mitsubishi Heavy Ind Ltd 熱交換器の漏洩検査方法
JP5773708B2 (ja) * 2011-03-31 2015-09-02 三菱重工業株式会社 熱交換器及び熱交換器の余寿命推定方法
US10197536B2 (en) 2012-05-11 2019-02-05 Basf Se Method for detecting damage to a hollow shaft
EP2902706A1 (en) * 2014-02-04 2015-08-05 Siemens Aktiengesellschaft Method for monitoring a combustor
CN104122192A (zh) * 2014-07-02 2014-10-29 上海大学 一种检测金属腐蚀状态的装置和方法
JP2015038422A (ja) * 2014-11-25 2015-02-26 三菱重工業株式会社 熱交換器及び熱交換器の余寿命推定方法
JP2024075284A (ja) * 2022-11-22 2024-06-03 三菱重工業株式会社 熱回収ボイラシステムの制御装置、熱回収ボイラシステムの制御方法、及びプログラム

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US4355536A (en) * 1979-10-02 1982-10-26 Westinghouse Electric Corp. Sludge measuring apparatus and ultrasonic probe assembly therefor
US4619143A (en) * 1984-08-24 1986-10-28 Dow Chemical (Nederl) B.V. Apparatus and method for the non-destructive inspection of solid bodies
US4685334A (en) * 1986-01-27 1987-08-11 The Babcock & Wilcox Company Method for ultrasonic detection of hydrogen damage in boiler tubes
US5050108A (en) * 1989-11-30 1991-09-17 Aptech Engineering, Inc. Method for extending the useful life of boiler tubes
US5351655A (en) * 1994-01-18 1994-10-04 The Babcock & Wilcox Company Acoustic emission signal collector manifold
US5526691A (en) * 1993-07-12 1996-06-18 The Babcock & Wilcox Company Detection of corrosion fatigue cracks in membrane boiler tubes
US6125703A (en) * 1998-06-26 2000-10-03 Mcdermott Technology, Inc. Detection of corrosion fatigue in boiler tubes using a spike EMAT pulser
US20030029232A1 (en) * 2001-08-08 2003-02-13 Felix Larry G. Coupon for measuring corrosion rates and system
US20030183537A1 (en) * 2002-04-02 2003-10-02 David Eden Method of spatial monitoring and controlling corrosion of superheater and reheater tubes
US6684706B2 (en) * 2000-11-29 2004-02-03 Cooper Cameron Corporation Ultrasonic testing system
US20040163969A1 (en) * 2003-02-21 2004-08-26 Breen Bernard P. Method of monitoring heat flux and controlling corrosion of furnace wall tubes
US20050126269A1 (en) * 2003-12-11 2005-06-16 Siemens Westinghouse Power Corporation Material loss monitor for corrosive environments
US20070125175A1 (en) * 2005-11-28 2007-06-07 Junker Warren R Steam generator nondestructive examination method

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JP2002106822A (ja) * 2000-06-22 2002-04-10 Nkk Corp ごみ焼却炉及びその操業方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4030370A (en) * 1976-02-25 1977-06-21 Continental Oil Company Transducer positioner for testing tubes from inside diameter
US4355536A (en) * 1979-10-02 1982-10-26 Westinghouse Electric Corp. Sludge measuring apparatus and ultrasonic probe assembly therefor
US4619143A (en) * 1984-08-24 1986-10-28 Dow Chemical (Nederl) B.V. Apparatus and method for the non-destructive inspection of solid bodies
US4685334A (en) * 1986-01-27 1987-08-11 The Babcock & Wilcox Company Method for ultrasonic detection of hydrogen damage in boiler tubes
US5050108A (en) * 1989-11-30 1991-09-17 Aptech Engineering, Inc. Method for extending the useful life of boiler tubes
US5526691A (en) * 1993-07-12 1996-06-18 The Babcock & Wilcox Company Detection of corrosion fatigue cracks in membrane boiler tubes
US5351655A (en) * 1994-01-18 1994-10-04 The Babcock & Wilcox Company Acoustic emission signal collector manifold
US6125703A (en) * 1998-06-26 2000-10-03 Mcdermott Technology, Inc. Detection of corrosion fatigue in boiler tubes using a spike EMAT pulser
US6684706B2 (en) * 2000-11-29 2004-02-03 Cooper Cameron Corporation Ultrasonic testing system
US6959603B2 (en) * 2000-11-29 2005-11-01 Cooper Cameron Corporation Ultrasonic testing system and method
US20030029232A1 (en) * 2001-08-08 2003-02-13 Felix Larry G. Coupon for measuring corrosion rates and system
US20030183537A1 (en) * 2002-04-02 2003-10-02 David Eden Method of spatial monitoring and controlling corrosion of superheater and reheater tubes
US20040163969A1 (en) * 2003-02-21 2004-08-26 Breen Bernard P. Method of monitoring heat flux and controlling corrosion of furnace wall tubes
US20050126269A1 (en) * 2003-12-11 2005-06-16 Siemens Westinghouse Power Corporation Material loss monitor for corrosive environments
US20070125175A1 (en) * 2005-11-28 2007-06-07 Junker Warren R Steam generator nondestructive examination method

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110087517A1 (en) * 2009-10-12 2011-04-14 Abbott Patrick D Targeted Equipment Monitoring System and Method for Optimizing Equipment Reliability
US8442853B2 (en) 2009-10-12 2013-05-14 Patrick D. Abbott Targeted equipment monitoring system and method for optimizing equipment reliability
US9212569B2 (en) 2010-10-19 2015-12-15 General Electric Company Systems, methods, and apparatus for determining online stress and life consumption of a heat recovery steam generator
US9279346B2 (en) 2010-10-19 2016-03-08 General Electric Company Systems, methods, and apparatus for determining online stress and life consumption of a heat recovery steam generator
EP2847584A1 (de) 2012-05-11 2015-03-18 Basf Se Verfahren zur erfassung von schädigungen an einer hohlwelle
WO2022005456A1 (en) * 2020-06-30 2022-01-06 Paneratech, Inc. Antenna-grating sensing system

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EP1811282A1 (en) 2007-07-25
JP2007192537A (ja) 2007-08-02
CN101004259A (zh) 2007-07-25

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