Increased operating profit by reducing financial penalties
Reduction of insurance costs
Avoiding unscheduled outages
Increased availability and tube life
Reduction of secondary damage
Increased personal safety
Why is early detection essential?
For Utilities -To prevent expensive secondary damage and unscheduled outages in boilers, feedwater heaters, headers, steam pipes and valves.
For Paper Mills -To prevent smelt water explosive reactions in recovery boilers.
For Process Plant -To provide early warning of leaks in steam pipes, valves and heat exchanges.
The real costs of undetected tube leaks
EPRI Report No RP1863 showed that electrical power generation plants have, on average, around 6% loss of plant availability due to boiler tube leaks.
The survey over USA & Europe found that boiler tube leaks were the single biggest cause of lost availability.
Detecting leaks by measuring make-up water or walking the boiler is very insensitive and usually gives information about the existence of a leak only when that leak is already large & creating serious secondary damage.
The Leak Detection System | Steam Leak | Lintvalve is designed to detect a steam leak the moment it begins, allowing time for a planned schedule to shut down the boiler at an optimum time, such as the weekend. Thus resulting in substantial reduction of repair times and costs with a consequent increase in availability and profits. The early detection of a tube leak will give financial savings which will easily exceed the initial capital cost of the detection system even at the first steam leak event.
Lintvalve has over 25 years experience in detecting leaks.
The first commercial leak detection system in the world was installed on a boiler in 1974. With more than 250 installations in over 20 countries world-wide Lintvalve can proudly claim more experience and success than any other company in the field.
Typical System Overview of Leak Detection System | Steam Leak | Lintvalve
The Leak Detection System | Steam Leak | Lintvalve consists of:
Patented Airborne Sensors: Lintvalve's acoustic microphone is shock and vibration resistant and 30 to 50 times more sensitive than piezo-electric microphones. This sensitivity enables the system to locate even very small leaks and gives you the time you need to plan a proper course of action for repair.
Plate Microphone: Piezo-electric based sensors, which use the boiler wall as a diaphragm to convert airborne audio signals into acoustic signals. The Lintvalve system uses plate microphones in areas where ash or salt cake build-up prevents the use of microphones which require an open pathway.
Structure-Borne Sensors: Piezo-electric based sensors measure ultrasonic sound generated by leaks in the boiler structure. Especially effective in lower furnace water wall area where hot slag readily blocks open pathways to a microphone or shatter sprays produce high levels of audio noise.
Ultra-Dynamics | Innovative Solutions for Industry
Ultra-Dynamnics Pty Ltd specialises in process control enhancements, electronic monitoring equipment and general consultancy for power generation, mining and manufacturing and all heavy industry. The product range can be divided into a number of areas including:
1. General Industry
On-line measurement of the ultraMOIST moisture using a microwave transmission technique which is suitable for application to conveyor belt as well as in-bin. The system has been applied to a wide range of industries for application to moisture measurement of paper to rock as well as other non-conducting materials. Ultra-Dynamics Pty Ltd has also developed a number of control strategies including drier control and water addition.
MAGNASAT Magnetic Susceptibility Meter provides a measurement of the magnetic properties of materials and has been particularly useful for the copper and mineral sands industries for the measurement of magnetite and other ferrous mineral contents of process materials.
Inflo Resometric Beltscale which provides the ultimate precision and stability of mass flow measurement
2. Power Industry
Lintvalve Steam Leak Detection System for the detection of steam leaks before they become a major costly repair problem
Promecon's Mecontrol range of on-line analysis equipment including:
- UBC for the measurement of unburned carbon in fly ash
- AIR for the measurement of air flow directly in ducts
- COAL for the measurement of pulverised fuel mass flow, air velocity and particle size analysis
- TEMP for the rapid measurement of temperature particularly in pulverising mills.