INSTALLATION AND SERVICE MANUAL BoilerSpection™ Model HD • Model SD
Confidential Information The material contained herein consists of information that is the property of LumaSense Technologies and intended solely for use by the purchaser of the equipment described in this manual. All specifications are subject to change without notice. Changes are made periodically to the information in this publication, and these changes will be incorporated in new editions.
Contents 1 General ........................................................................................................................... 5 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 Introduction .................................................................................................................... 9 2.1 2.2 2.3 2.4 3 Information about the user manual ........................................................................ 5 Legend .........................................................
Maintenance ................................................................................................................. 35 4.1 4.3 4.4 4.5 4.6 5 Troubleshooting ............................................................................................................ 38 5.1 5.2 5.3 5.5 5.6 6 7.2 7.3 7.4 BoilerSpection HD System Diagrams...................................................................... 55 7.1.1 HD Borescope Assembly .......................................................
1 General 1.1 Information about the user manual This manual provides important information that can be used as a work of reference for installing, operating, and maintaining your LumaSense BoilerSpection system. It is important that you carefully read the information contained in this manual and follow all safety procedures before you install or operate the system. To avoid handling errors, keep this manual in a location where it will be readily accessible. 1.
Operation of an intentional, unintentional, or incidental radiator is subject to the conditions that no harmful interference is caused and that interference must be accepted that may be caused by the operation of an authorized radio station, by another intentional or unintentional radiator, by industrial, scientific and medical (ISM) equipment, or by an incidental radiator.
1.7 Service Request or Repair Contact LumaSense Technologies Technical Support in case of a malfunction or service request. Provide clearly stated details of the problem as well as the instrument model number and serial number. Upon receipt of this information, Technical Support will attempt to locate the fault and, if possible, solve the problem over the telephone.
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2 Introduction The LumaSense BoilerSpection™ system is a comprehensive turnkey solution that provides continuous imaging inside boilers and furnaces. The core components that comprise the system are the 320x240 IR imager filtered at 3.9 µm, a borescope lens, protective hardware that includes cooling, and an auto-retract device with controls.
The LumaSense BoilerSpection system uses a specific wavelength of infrared for imaging that enables the system to see through flames and hot combustion gas inside a boiler or furnace. This allows for clear views of boiler walls, tubes and the buildup of slag through the flames during normal and continuous operation. These imagers are made in the USA using state-of-the-art microbolometer focal plane arrays with integrated narrowband (aka “notch”) spectral filters near 3.
Figure 3: System Block Diagram Image data from multiple BoilerSpection cameras is collected, controlled, and analyzed from a single control room controller. There is a central interface enclosure (i.e., "data panel") that is mounted in the plant near the cameras. All cameras have Ethernet connections to this panel and there is a fiber optic link from this panel to the server located in the control room. Operators can view and control all cameras remotely using the software from the control room.
Protective Enclosure Borescope Lens Infrared Camera Figure 4: BoilerSpection HD Camera Assembly This entire assembly of the camera, lens, and enclosure is mounted just outside the wall of the boiler on an automatic retraction system. Figure 5: BoilerSpection HD Assembly mounted on an Automatic Retraction System The retraction system's integrated controls automatically retract the camera system from the boiler in the event of air or power failure.
2.3 System Components The LumaSense BoilerSpection system is delivered in separate boxes with the components as described below. 2.3.1 BoilerSpection Camera and Lens Assembly Inside the rugged BoilerSpection enclosure is an exceptionally accurate 320 x 240 focal-plane array microbolometer imaging camera with sensitivity of 0.08 °C. The camera has a standard Ethernet interface that simplifies communications and networking in the plant.
Each camera has its own independently operated retraction system. Included with each is a regulator for the compressed air supply, pressure switch, check valve, ball valve, solenoid, and a controls enclosure. The retract device also includes all air lines and connections that are required for the system. It also includes a set of air filters for each camera/retract location to ensure that clean air is supplied to the BoilerSpection lens and to the system's vortex coolers.
another on the boiler/furnace. The PDE also includes individual circuit breakers for each camera. If your site specific system design routes AC power directly to each camera location, then you most likely will not have a PDE. Instead the circuit breaker for each camera will be located in the Retract Controls enclosure for each camera. 2.3.
Figure 11: Block diagram of software network architecture The BoilerSpec Web Server View Only application outputs streaming video of the images captured by the BoilerSpection cameras using a web browser interface. Access to the images is controlled by Microsoft’s Internet Information Services (IIS) that must be provided by and configured by the user’s IT department. IIS is the web server interface that allows the user to control access and security to the streaming images from the BoilerSpection system.
2.4.2 Hardware - Control Room Options Large screen display for control room Large display for user interface and display of the boiler images in the control room. PC-over-IP Network Portal This is a network switch that will allow the location of display and user interface (UI) peripherals to be located away from the IPC and connected via Ethernet. RAID Memory Upgrade The IPC server can be upgraded to include a RAID memory system per the customer's request.
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3 BoilerSpection Installation Guide BoilerSpection is an innovative tool helping today’s plant manager cope with ever increasing emissions, fuel flexibility, and increased efficiency expectations. BoilerSpection includes state-of theart optics, infrared cameras, an auto-retraction device, networking components, and software to control the entire system remotely.
While it is not possible to cover all possible installation circumstances, this chapter covers the requirements common to all installations and provides suggested installation steps and guidelines. For assistance with your specific installation, please contact LumaSense Technologies and consider ordering on-site installation and commissioning support. 3.1 3.1.
1-2 weeks prior Pull and terminate communication cables from camera mounting locations to field switch and from field switch to control room. Install air lines. Install electrical conduit and pull main electrical supply lines. Installation week: Stage system components at each camera location. Install computers/servers in computer rack room or control room. Attached mounting plates (weld-on or bolt-on). Slide camera wall box into mounting plate and tack weld Camera system in position.
3.1.3 Preparing the Boiler Select the location on the furnace or boiler where you will be mounting each of the BoilerSpection camera systems. Consideration should be given to the location of the desired scene to be monitored, the opening in the wall, access to the site, support members, internal furnace/boiler conditions, etc. Selecting the best location can depend on the unique behavior of individual furnaces; and final location decisions must be made by the user.
Figure 14: Main components in a BoilerSpection Camera and Retraction Device System The main components in a BoilerSpection Camera and Retraction Device System are: BoilerSpection HD Components BoilerSpection SD Components A Mounting Plate, 12" x 18" x 1/2" stainless steel typical Mounting Plate, 12" x 18" x 1/2" stainless steel typical B 1 in. NPT air to shutter box (5 psi at 20 SCFM typical) 1 in.
To prepare the boiler: 1. After selecting the mounting location, install and/or retrofit existing ports to accommodate BoilerSpection system. 2. Affix the mounting plate “A” (See Figure 14) to the furnace wall. Ensure that there is adequate room for a safety zone behind the mounting location, where the camera system can fully retract. Caution: It is important that you label this area CAUTION. Note: LumaSense offers both weld-on and bolt-on options for the mounting plates.
Figure 16: Example of properly mounted air filtration system 3.3 3.3.1 Preparing the Camera Preparing the Camera for HD Systems Mount the BoilerSpection camera to the retract device on the floor or catwalk near the selected furnace wall mounting location. The retract device will need to be manually pulled to the fully retracted position to allow the camera’s lens to slide into the retract device’s wall box sleeve and the base of the camera to mate with the mounting bracket on the retraction slide. 3.3.
3.4 Mounting the Camera System In this step, the system will be mounted and aimed. You will need to determine the proper mounting angle of the retraction systems to the desired target locations. This can be undertaken while the furnace is online (hot) or during an outage (cold), but the process will be easier if the furnace is online. Figure 17: Example Closed and Open Retraction System Mounting Angles Note: The maximum angle possible from vertical and horizontal is +/- 15 degrees.
To Mount the Camera and Retract Device: Lift the camera system and slip the wall box of the retract device into the mating hole on the mounting plate. Figure 18: BoilerSpection HD Mounting Detail Figure 19: BoilerSpection SD Mounting Detail Note: There is enough tolerance between the wall box and the mounting plate hole to allow the system to be aimed as shown in Figure 17. The maximum angle possible from vertical and horizontal is +/- 15 degrees. To work with a ‘hot’ furnace: 1.
3.5 Making the Connections In order for the BoilerSpection system to operate correctly, the supplied hardware must be properly attached to the computer and power supplied to the various parts of the system. 3.5.1 Air Connections All hoses are provided with the BoilerSpection system and run from the air filtration system to the camera and the retract device. The hoses are braided stainless steel and the standard length is 15 foot (4.5m).
Figure 21: HD Camera Air Filtration System A. 1” Ball Valve B. 1” Regulator (to shutter box for purge) C. 1” Regulator/Pressure Switch Assembly D. Pre-Filter E. Final-Filter F. ½” Regulator (to camera enclosure for cooling) G. ½” Regulator (to lens assembly for cooling and purge) H. 1” Check Valve I. Solenoid Assembly J. Power cable K. Power cable L. Final-Filter Drain M.
A B C D K E J F I H G Figure 22: SD Camera Air Filtration System A. ½” Regulator B. Final-Filter C. Pre-Filter D. 1” Regulator E. 1” Check Valve F. Brass Pressure Switch G. Power Cable H. Conduit Body I. Power Cable J. Solenoid Assembly K. ½” Check Valve Follow standard practices to ensure that air lines are clean before connecting. Check for proper flow after installation. Plant air supply to the air filtration system is through a 1” NPT ball valve fitting.
3.5.2 Electrical Connections – BoilerSpection HD 1. Connect temporary power to the camera. In a later step of the installation, the permanent power and flexible conduit will be installed. There are two conduit connections at the rear of the housing. Use one for the power connections and the other for the network cable. One hole is ¾-inch and the other is ½-inch (see Figure 23). Connect a VDC power cable through the ¾-inch hole. (see Figure 25).
3.5.3 Electrical Connections – BoilerSpection SD 1. Connect temporary power to the camera. In a later step of the installation, the permanent power and flexible conduit will be installed. A power connection is located at the rear of the housing. Connect a VAC power cable to the power connector. (see Figure 25). Figure 25: BoilerSpection SD Power Connection 2. Connect power to the Retraction System Control Box.
3.5.4 Network Connections The Field Switch Enclosure (FSE) provides a central connection point for all communication cables from the BoilerSpection cameras. 1. Connect an Ethernet (Cat-5 or Cat-6) cable through the ½-inch hole located at the rear of the housing of the BoilerSpection HD camera system.
2. Connect the other end of the Ethernet cable to the Field Switch Enclosure (FSE). The FSE includes an industrial Ethernet switch with a fiber optic port to link to the control room. The fiber optic link can be up to 250m (820') to the Imaging Processor/Controller (IPC) server located in the control room. 3. Route the fiber optic link from the FSE to the control room. 3.6 Setup and Configuration The computer is provided preconfigured for your installation.
4 Maintenance The BoilerSpection™ system is designed to operate continuously in harsh environments, but filter replacement and other maintenance measures need to be implemented as described in this section to avoid preventable wear or damage to the system. 4.1 4.1.
4.1.2 Preventive Maintenance Tools or Parts Required Item Description 1 Clean lens tip Check when image quality degrades 2 Replace 3 µm 1st stage air filter, if necessary Yearly or as required 3 Replace 0.3 µm 2nd stage air filter, if necessary Yearly or as required 4 Exercise retraction device Monthly 4.2 Maintenance Interval Checking Air Filter Automatic Drains The drains should be checked weekly to be sure they are working properly.
4.5 Ordering Replacement Parts To order replacement parts, contact your local LumaSense Representative or call LumaSense Technologies at 1-800-631-0176 or 1-408-727-1600.
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5 Troubleshooting 5.
Change in image color Accuracy out of spec Grainy/poor image Noise out of spec Shifted Image Alignment shifts within the enclosure due to mechanical vibrations Check mechanical fittings and enclosure for loose or out of place components and repair Remote focus will not adjust (HD systems only) Mechanical failure – focusing motor caused by improper tuning of retraction system Service camera Loss of image Loss of communication Check connection to the camera; investigate the possibility of an IP ad
5.4 Retraction/Filtration Symptom Probable Cause Corrective Action Immediate retraction Loss of air, air pressure caused by site supply failure Check supply of air and power Failure to retract Mechanical failure of the retraction system Check mechanical fittings and enclosure for loose or out of place components and repair Lens failure due to heat.
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6 Principles of Thermal Imaging All materials above 0 degrees Kelvin (-273 degrees C) emit infrared energy. The infrared energy emitted from the measured object is converted into an electrical signal by the imaging sensor in the camera and displayed on a monitor as a color or monochrome thermal image. The basic principle is explained in the following sections. 6.
6.2 Emissivity Infrared radiation is energy radiated by the motion of electronics, atoms and molecules on the surface of an object, where the temperature of the object is more than absolute zero. The intensity of the emittance is a function of the temperature of the material. In other words, the higher the temperature, the greater the intensity of infrared energy that is emitted.
6.3 Blackbody Radiation Note: A blackbody is a theoretical surface, which radiates energy according to Planck's law, and absorbs all the radiative energy it receives. It does not reflect or transmit any IR energy. Perfect blackbody surfaces do not exist in nature. The emissivity of a body is defined formally by the equation below as the ratio of the radiant energy emitted by the body to the radiation, which would be emitted by a blackbody at the same temperature.
, In radiation of a normal object, as the emissivity is (<1) times of the blackbody, multiply above equation by the emissivity. The following figures show the spectral radiant emittance of a blackbody. (a) is shown by logarithmic scale and (b) is shown by linear scale. Figure 30: Spectral radiant emittance of a blackbody 6.
In order to obtain the true temperature of an object, it is necessary to obtain the emissivity correctly. Therefore, the emissivity of the object has to be measured by using a blackbody-type source which is closest to an ideal blackbody as possible. The blackbody-type source can be designed to meet the conditions pointed out by Kirchoff where “the radiation within an isothermal enclosure is blackbody radiation.
the blackbody-type source are then measured with the radiation thermometer and the resulting energy ratio is then used to define the emissivity as follows: EK : energy of blackbody-type source ES: energy of measured object X: emissivity of measured object Where, EK : ES = 1 : X 3. Determination by ratio — Option 2 An object, resembling a blackbody, is attached to a heat source to make the temperature of the blackbody part and the measuring object the same.
2. Have no high temperature object behind the measured object, such as the sun shining on the back of the measured object. 3. Do not allow direct sunlight to strike thermal imager. 4. Do not allow obstacles such as dust or vapor (which attenuates the infrared signal) between the measured object and the thermal imager. 6.7 Practical Measurement There are a number of methods for correcting emissivity in order to obtain the true temperature. The correction procedure with each method will be explained next.
6.8 Emissivity of Various Materials From “Infrared Radiation, a Handbook for Applications” by Mikael A.
BoilerSpection HD/SD Manual Principles of Thermal Imaging 51
BoilerSpection HD/SD Manual Principles of Thermal Imaging 52
BoilerSpection HD/SD Manual Principles of Thermal Imaging 53
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7 System Diagrams 7.1 BoilerSpection HD System Diagrams Figure 32: BoilerSpection HD Model Diagram Section 7.1.1 – HD Borescope Assembly Drawing o Figure 33: HD Dimensions with Borescope Lens Assembly Section 7.1.2 – HD Mounting Plate Drawings o Figure 34: Drawing of standard HD weld-on mounting plate o Figure 35: Drawing of typical HD bolt-on mounting plate Section 7.1.
7.1.
7.1.
Figure 35: Drawing of typical HD bolt-on mounting plate BoilerSpection HD/SD Manual System Diagrams 58
7.1.
Figure 37: HD Air Filtration System Dimensions BoilerSpection HD/SD Manual System Diagrams 60
Figure 38: HD Air Filtration System Mounting Hole Pattern BoilerSpection HD/SD Manual System Diagrams 61
7.1.
Figure 40: HD Retraction System Dimensions – Inserted State BoilerSpection HD/SD Manual System Diagrams 63
Figure 41: HD Retraction System Dimensions – Retracted State BoilerSpection HD/SD Manual System Diagrams 64
7.2 BoilerSpection SD System Diagrams 24” Lens Model 18” Lens Model 36” Lens Model Figure 42: BoilerSpection SD Model Diagrams Section 7.2.1 – SD Borescope Assembly Drawings o Figure 43: SD Dimensions with 18” Borescope Lens Assembly o Figure 44: SD Dimensions with 24” Borescope Lens Assembly o Figure 45: SD Dimensions with 36” Borescope Lens Assembly Section 7.2.
7.2.
Figure 44: SD Dimensions with 24” Borescope Lens Assembly BoilerSpection HD/SD Manual System Diagrams 67
Figure 45: SD Dimensions with 36” Borescope Lens Assembly BoilerSpection HD/SD Manual System Diagrams 68
7.2.
Figure 47: Drawing of typical SD bolt-on mounting plate BoilerSpection HD/SD Manual System Diagrams 70
7.2.3 SD Air Filtration System Mechanical Drawings A B C D K E J F I H G Figure 48: SD Air Filtration System Components A. ½” Regulator B. Final-Filter C. Pre-Filter D. 1” Regulator E. 1” Check Valve F. Brass Pressure Switch G. Power Cable H. Conduit Body I. Power Cable J. Solenoid Assembly K.
Figure 49: SD Air Filtration System Dimensions BoilerSpection HD/SD Manual System Diagrams 72
Figure 50: SD Air Filtration System Mounting Hole Pattern BoilerSpection HD/SD Manual System Diagrams 73
7.2.
Figure 52: SD Retraction System Components BoilerSpection HD/SD Manual System Diagrams 75
Figure 53: SD 18” Retraction System Dimensions BoilerSpection HD/SD Manual System Diagrams 76
Figure 54: SD 24” Retraction System Dimensions BoilerSpection HD/SD Manual System Diagrams 77
Figure 55: SD 36” Retraction System Dimensions BoilerSpection HD/SD Manual System Diagrams 78
7.
Figure 57: Field Switch Enclosure Configuration Wiring (With Circuit Breaker) BoilerSpection HD/SD Manual System Diagrams 80
Figure 58: Field Switch Enclosure Configuration Wiring (Without Circuit Breaker) BoilerSpection HD/SD Manual System Diagrams 81
7.
Figure 60: Power Distribution Enclosure Electrical Schematic BoilerSpection HD/SD Manual System Diagrams 83
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8 Appendix Specifications Infrared Imaging Camera and Lens Resolution 320 x 240 pixels Wavelength 3.9 µm Detector Type Uncooled focal plane array Measurement Range HD: 400°C to 1600°C (752°F to 2,912°F) SD: 500°C to 1600°C (932°F to 2,912°F) Lens Diameter HD: Outer diameter of lens system is 3.39” (86 mm) SD: Outer diameter of lens system is 1.
8.2 Table of Figures Figure 1: Pendant Section Inside a Coal-Fired Boiler monitored using the BoilerSpection system ....... 9 Figure 2: Screenshot of LumaSense Analysis Software .......................................................................... 9 Figure 3: System Block Diagram ........................................................................................................... 11 Figure 4: BoilerSpection HD Camera Assembly .....................................................................
Figure 52: SD Retraction System Components ..................................................................................... 75 Figure 53: SD 18” Retraction System Dimensions ................................................................................ 76 Figure 54: SD 24” Retraction System Dimensions ................................................................................ 77 Figure 55: SD 36” Retraction System Dimensions .......................................................................
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9 Index A Air Connections 28 Air Filtration System 24, 59, 71 Appendix 85 Automatic Retraction System 13 B Boiler Preparation 22 BoilerSpection Camera and Lens Assembly 13 BoilerSpection HD Assembly 10 BoilerSpection HD System Diagrams 55 BoilerSpection Installation Guidelines 20 BoilerSpection SD System Diagrams 65 BoilerSpection System 19 BoilerSpec™ Software 15 C Camera Preparation 25 D Disposal / Decommissioning 7 E Electrical Connections 31, 32 F Field Switch Enclosure (FSE) 14, 79 Field Switch En
SD Retraction System Mechanical Drawings 74 Service Request or Repair 7 Setup and Configuration 34 Shipments to LumaSense for Repair 7 Spare Parts 36 Specifications 85 System Components 13 System Diagrams 55 System Overview 10 T Table of Figures 86 Theory of Operation 9 Training 5 Troubleshooting 39, 40, 41 U Unpacking and Inspection 6 BoilerSpection HD/SD Manual Index 90
