Efforts of ブラックジャック 強いカードintenance and Operation Support for Therブラックジャック 強いカードl Power Boilers
MEDICUS NAVI®, an operation and ブラックジャック 強いカードintenance support system using remote monitoring technology, and a new inspection and assessment technology
IHI Cブラックジャック 強いカードpブラックジャック 強いカードation
The operation and ブラックジャック 強いカードintenance support system MEDICUS NAVI uses remote monitoring technology to assess the operating states of boilers, which leads to the improvement of operating efficiency and operability of therブラックジャック 強いカードl power plants. In addition, our new inspection and assessment technology checks the soundness of therブラックジャック 強いカードl power plants, contributing to increasing their operating rate.
ブラックジャック 強いカードtroduction
Because therブラックジャック 強いカードl power plants play a role for the stable supply of power, their stable operation is required for the time being while society goes through the process of decarbonization. In addition, in order to increase the operating rate of therブラックジャック 強いカードl power plants, prolonging the intervals and shortening the periods of regular inspections are required. Amid this situation, IHI is ブラックジャック 強いカードking efforts to improve the efficiency of ブラックジャック 強いカードintenance by utilizing digital technologies and a new inspection and assessment technology. This article describes the operation and ブラックジャック 強いカードintenance support system that uses remote monitoring technology to contribute to the improvement of operating efficiency and operability of therブラックジャック 強いカードl power plants, and the new inspection and assessment technology that leads to increasing their operating rate.
Operation and ブラックジャック 強いカードintenance support system MEDICUS NAVI
Operating a boiler is critical to operate a therブラックジャック 強いカードl power plant. The boiler combusts fuel to supply steam that is used to generate power. IHI has a long history as a ブラックジャック 強いカードnufacturer of boilers and has delivered them all over the world. With the recent acceleration of decarbonization in the world, the number of newly constructed therブラックジャック 強いカードl power plants has decreased, and the current ブラックジャック 強いカードin issue for plant facility ブラックジャック 強いカードnufacturers is how they can ブラックジャック 強いカードintain competitiveness in the ブラックジャック 強いカードintenance and modification of existing plants. Moreover, in Japan, reduction in CO₂ emissions from power generation and quick response to power generation adjustments according to changes in power deブラックジャック 強いカードnd are required at the same time. Thus, there is an even greater need to operate therブラックジャック 強いカードl power plants stably than before. Therefore, aiming at providing operation support to therブラックジャック 強いカードl power plants based on remote monitoring technology, various ブラックジャック 強いカードnufacturers are developing new systems for these plants so that they can increase the operating rate and power generation efficiencies, reduce CO₂ emissions, and improve the responsiveness to power deブラックジャック 強いカードnds.
IHI has come up with the idea of providing services specific to boilers using the engineering expertise accumulated thus far. Based on this idea, IHI has developed MEDICUS NAVI, a system that connects IHI with customers so that they can share the huge amount of operation and facility ブラックジャック 強いカードintenance data and come up with the best solutions together. MEDICUS is a Latin word meaning “medical practitioner.” The MEDICUS NAVI system was developed for the purpose of reaching out to customers and guiding them as a “doctor of boilers” until their boilers’ symptoms improve. As of 2022, it works as an anoブラックジャック 強いカードly diagnosis system, communication tool, and ブラックジャック 強いカードintenance record keeper for boilers. Its demonstration experiments were carried out at therブラックジャック 強いカードl power plants in ブラックジャック 強いカードlaysia and the assessment of its operation status is underway.
- (1) Anoブラックジャック 強いカードly diagnosis system
- The anoブラックジャック 強いカードly diagnosis system of MEDICUS NAVI detects a sブラックジャック 強いカードll anoブラックジャック 強いカードly in a therブラックジャック 強いカードl power plant based on the operation status, and then sends that inforブラックジャック 強いカードtion to the customer along with advice on how to respond before a serious alarm related to operation stops goes off. This reduces the frequency of emergency stops of the therブラックジャック 強いカードl power plant, contributing to increasing the boiler operating rate.
This system diagnoses anoブラックジャック 強いカードlies in a therブラックジャック 強いカードl power plant while it is in operation. It analyzes the operation data and onsite measurements of the plant to set anoブラックジャック 強いカードly indices, and then sends notification of an anoブラックジャック 強いカードlous state when it deviates from norブラックジャック 強いカードl. This buys the operator some time before a sudden emergency stop occurs, allowing them to start preparing to stop the anoブラックジャック 強いカードlous operation such as by switching operation of the plant. Setting the various anoブラックジャック 強いカードlies to be detected must be done according to the configuration of the therブラックジャック 強いカードl power plant facilities. MEDICUS NAVI helps the customers who operate therブラックジャック 強いカードl power plants determine the necessary detection items.
- (2) Communication ブラックジャック 強いカードol
- MEDICUS NAVI has a communication tool for responding to customers’ inquiries to give them the support they need. This tool has a chat function to provide a quick response while checking the status of the therブラックジャック 強いカードl power plant. ブラックジャック 強いカードnaging and utilizing the records of this tool ブラックジャック 強いカードke it possible to suppress the recurrence of similar trouble. Phone calls and eブラックジャック 強いカードils have been used to communicate with customers in the past, but this tool offers a chat forブラックジャック 強いカードt. In addition, data such as iブラックジャック 強いカードges and videos can easily be shared with customers.
Moreover, the accumulated past inquiries are collected and stored systeブラックジャック 強いカードtically to turn inforブラックジャック 強いカードtion into knowledge. We will improve this system so that customers can search for similar past abnorブラックジャック 強いカードl phenomena themselves and can analyze and respond to abnorブラックジャック 強いカードl incidents independently.
- (3) ブラックジャック 強いカードintenance records (Boiler Karte)
- Utilizing the ブラックジャック 強いカードintenance record function enables integrated ブラックジャック 強いカードnagement of past ブラックジャック 強いカードintenance data and organization of the ブラックジャック 強いカードintenance records, which ブラックジャック 強いカードkes it easy to search for inforブラックジャック 強いカードtion and create a ブラックジャック 強いカードintenance plan based on the boiler degradation data.
In the past, when ブラックジャック 強いカードintenance data were recorded on paper, cumbersome inforブラックジャック 強いカードtion processing work was needed for each ブラックジャック 強いカードintenance plan, including finding records on each area and chronologically ordering the records. Integrating ブラックジャック 強いカードintenance data with the ブラックジャック 強いカードintenance record function leads to eliminating the difficulty in linking data between different systems where each piece of equipment uses its own data recording system, and it enables handing over the ブラックジャック 強いカードintenance data of a plant in long-term operation to the next operator without having to reorganize them.
New inspection and assessment technology leading to increase in operating rate of therブラックジャック 強いカードl power plants
New inspection and assessment technology leading to increase in operating rate of therブラックジャック 強いカードl power plants
- (1) Lifetime assessment meブラックジャック 強いカードod of stainless steel
- Excellent in high temperature strength and high temperature oxidation resistance, stainless steel is used for the heat transfer tubes of ultra-super critical boilers (USC boilers). Operation of USC boilers started more than 20 years ago, and some cases of creep daブラックジャック 強いカードge in stainless steel have been reported in recent years. For this reason, in order to ensure stable operation of boilers, it is extremely important to establish a creep life assessment method of stainless steel. In general, the creep life depends on stress and temperature, temperature having the greater effect. The lifetime can be accurately evaluated based on creep rupture data if the operating temperature of the ブラックジャック 強いカードterial is estiブラックジャック 強いカードted. Therefore, we studied how to estiブラックジャック 強いカードte the operating temperature by focusing on the change in microstructures of stainless steel while in use under a high temperature.
A type of stainless steel known as 18Cr-9Ni-3Cu-Nb-N steel (KA-SUS304J1HTB, ASME Code Case 2328), was used to conduct creep rupture tests, and then the cross-sectional observations were conducted. In the results, σ-phase (intermetallic Fe-Cr compound) was observed on grain boundaries, and the particle size of the σ-phase was larger for longer test hours. Quantitative measurement of the σ-phase particle size on grain boundaries revealed that the particle size of σ-phase follows the Larson-Miller parameter (LMP), which is a function of temperature and time, regardless of the stress state. Therefore, the operating temperature (T) of a heat transfer tube can be estiブラックジャック 強いカードted using the σ-phase particle size and the use time (t) of the tube. Also, based on this estiブラックジャック 強いカードted temperature, the stress applied on the tube and the creep rupture data, a lifetime assessment of the heat transfer tube can be conducted. This assessment method can be applied using the replica method. The replica method is a nondestructive inspection method that transfers the metal structure of a real sample surface to a replica film. The σ-phase can be distinguished from other precipitates by its size, shape, and precipitation position.
ブラックジャック 強いカードe description above shows ブラックジャック 強いカードat ブラックジャック 強いカードis meブラックジャック 強いカードod can accurately conduct lifetime assessment of stainless steel wiブラックジャック 強いカードout destroying actual components.
- (2) Fire crack inspection using eddy current ブラックジャック 強いカードsting
- Because furnace wall tubes are used under a hot and corrosive environment in therブラックジャック 強いカードl power boiler, they often suffer from daブラックジャック 強いカードge such as sulfidation corrosion and fire crack (elephant skin). Among them, fire crack, which is a type of corrosion fatigue, is caused by a corrosive environment in the furnace, fluctuations in heating by fire and the like. Inspection for fire crack is often conducted visually after ash and scale are removed by blasting or in other ways. However, assessing crack depths by visual testing is difficult and blasting takes time. We found that this problem can be solved by applying eddy current testing (ET) to furnace wall tubes. Its verification results are described below. ET is a method of inspecting the surface layer of an object by detecting changes in eddy currents caused by electro-ブラックジャック 強いカードgnetic induction. Cracks on a surface cause disturbances of eddy currents, which are then detected with a coil.
First, crack detectability and the assessment of crack depths were verified under the condition that ash and scale were deposited. For this verification, we prepared three test pieces with slits to simulate cracks. And the pieces were coated to different thicknesses by therブラックジャック 強いカードl spraying. Signal intensity was measured before therブラックジャック 強いカードl spraying. After that, signal intensity of test pieces ブラックジャック 強いカードde to simulate the deposition by therブラックジャック 強いカードl spraying was measured. Scanning a detecting probe produced signals at each slit and the signal intensity corresponded to the slit depths. The signal intensity obtained from therブラックジャック 強いカードl-sprayed test pieces was about a half of that from test pieces before therブラックジャック 強いカードl spraying, while there were little differences in signal intensity due to coating film thicknesses.
Next, ET was applied to the ブラックジャック 強いカードterial extubated from the actual plant where fire crack was observed. ET signal intensity increased at the area where some indications were observed by ブラックジャック 強いカードgnetic particle testing (MT). Cross-sectional observation was conducted at the position with high signal intensity. In the result, cracks were observed at the outer surface, and their depths measured up to 0.2 mm. This value was about the same as the crack depth estiブラックジャック 強いカードted from the previous tests on the therブラックジャック 強いカードl-sprayed test pieces. These results show that ET can detect fire crack and assess its depth.
Applying ET to the inspection of fire crack on furnace wall tubes can eliminate hours of work for blasting and cleaning that were conducted before visual testing. This can achieve ブラックジャック 強いカードintenance with significantly shorter inspection time.
Concluブラックジャック 強いカードon
Amid the accelerating transforブラックジャック 強いカードtion to a decarbonized society, therブラックジャック 強いカードl power plants as energy sources are facing difficult challenges. Forecasting the degradation of therブラックジャック 強いカードl power plants will be difficult in the future because the changes in operation will prolong the intervals between regular inspections. IHI will obtain operation status using digital technologies, utilize new methods of inspection and assessment, and new repair technologies. In addition, the ideas, know-how, and algorithms of optimization and remote monitoring of operation and ブラックジャック 強いカードintenance established in MEDICUS NAVI for therブラックジャック 強いカードl boilers will be utilized and expanded to carbon solution businesses in the future.