A Diagnostic Method Based on Active Thermography for the Degradation Assessment of Power Plant Boiler Tubes

Proper maintenance management of power infrastructure requires inspections, in order to gather knowledge about the facility’s current condition. For this purpose, periodic diagnostic tests are carried out, not only to determine the current state, but to also predict future conditions, and subsequently plan for the scope of necessary repair work. Currently, in the case of heat screens of power boilers, the diagnostic process takes many days, is very expensive, and usually does not cover the entire screen area. Therefore, it is necessary to develop new, noninvasive diagnostic methods. This study presents the concept and research for an alternative method of locating places with excessive energy boiler screen degradation that require replacement. It was assumed that the new method should be fast, require no scaffolding assembly, and permit checking of the entire screen surface; this is unlike the methods used currently, which require manual checking of selected screen tubes. The proposed method is based on active thermography, in which heat flux is forced by the liquid flowing inside the screen. Tests were carried out based on a model of an axial-symmetric system in the form of a tube, with controlled reductions in the wall thickness. An experiment was carried out many times by recording the pipe surface temperature in many characteristic places (different thicknesses of the tube walls) with a thermal imaging camera. A temperature change was forced by a controlled flow of hot or cold water. The methods of analysis were proposed and verified, allowing firstly, detection of places with a reduced wall thickness, and secondly, estimations of the wall thickness (i.e., excessive degradation). For the best-proposed model (one of the four analyzed), all of the thickness changes were detected, and the limit error of thickness obtained was 0.3 mm.