Wireless improves Barking Power efficiency 01 August 2012

Wireless improves Barking Power efficiency

Barking Power engineers are reporting improved availability and efficiency at its CCGT (combined cycle gas turbine) plant since installing Emerson's Rosemount 708 wireless acoustic transmitters to identify failed steam traps, leaking valves and boiler tube leaks.

The instrumentation is helping plant engineers at the Thames Power Services operated power station to avoid substantial costs for lost steam and feedwater, as well as lost revenue from plant downtime.

"Improving process performance is all about understanding what is happening around the plant and being able to respond quickly to any problems," observes Ian MacDonald, senior control systems engineer at Barking Power.

"Emerson's smart wireless technology enables us to introduce additional measurement points quickly and cost effectively at any location, so we can gather additional information to identify potential faults," he adds.

To improve identification of failed steam traps and problem valves, Barking Power installed 35 of Emerson's wireless transmitters across the plant, explains MacDonald.
Should a steam trap fail or a small leak begin, an acoustic device transmits changes in sound and temperature, which are configured to alert operators of a potential problem.

The plant began gaining the benefits immediately, he says, as a leak from a high pressure superheater steam trap was identified that would have cost £1,400 for every 24 hours of lost operation.

The plant installed 15 additional acoustic transmitters to monitor other problematic areas, including vent valves that can stick during start-up and pressure relief valves that don't seat correctly.

Previous manual monitoring was not only time-consuming but also failed to indicate when or why a release occurred, increasing the chances of a safety, regulatory or environmental incident.

The new wireless devices enable precise monitoring and alert operators when valves have opened for as little as a single second.

The wireless acoustic transmitters have also been installed to identify leaking boiler tubes, which not only reduce performance but also waste large amounts of costly boiler feed water.

Data is fed into the plant's existing Emerson Ovation control system, where noise levels can be trended to identify gradual changes. Repairs can then be scheduled during normal off-times to maintain maximum plant availability and avoid forced downtime.

"Having already installed Emerson's smart wireless THUM adaptors for access to 'stranded' HART diagnostic data in traditional field devices, we were very familiar with the technology and confident about using it in other applications," comments MacDonald.

"The mobility and flexibility of the battery powered wireless devices also allow us to run trials and move devices to different areas without having to lay temporary cables. As a result, we can spot early problems and improve response to malfunctioning equipment – enabling better planning and utilisation of maintenance resources."

Brian Tinham

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