ALL TM

Acoustic Leak Locator

Operation & Installation Manual

Acoustic Monitoring International, Inc.

www.acousticmonitoring.com

Listening is our Business

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 CONTENTS
Preface iv
AMI’s History and Information v
Technical Support vi
Warning and Caution Information vii

CHAPTER 1 INTRODUCTION

1.1 Introduction 1-2

1.1.1 System Features 1-3
1.1.2 System Overview 1-4
1.1.2.1 Hardware 1-4
1 .1.2.2 Software 1-5
1.1.2.3 Sensors and Preamplifiers 1-6
1.2 Computer and Software Overview 1-7
1.3 Airborne Acoustic Activity Monitor System Overview 1-8
1.4 Structure Borne Acoustic Activity Monitor System 1 - 10

CHAPTER 2 ACOUSTIC LEAK LOCATOR SYSTEM DESCRIPTION

2.1 Airborne Waveguide . 2-2

2.2 Structure Borne Waveguide 2-3
2.3 Airborne Sensor/Low Noise Cable 2-4
2.4 Structure Borne System Sensor/Low Noise Cable 2-5
2.5 Preamplifiers 2-6
2.6 Dual Signal Processor & Relay I/O Modules 2-8
2.7 Control Unit 2-9
2.8 Power Unit 2 - 10
2.9 Enclosure and Bus 2 - 11

CHAPTER 3 ACOUSTIC LEAK LOCATOR SYSTEM SPECIFICATIONS

3.1 Airborne Waveguide 3-2
3.2 Structure Borne Waveguide 3-2
3.3 Airborne Sensor/Low Noise Cable 3-2
3.4 System Architecture and Functional Description 3-4
3.5 Control Module 3-4
3.6 Dual Signal Processor 3-5
3.7 Enclosure 3-6
3.8 Operator/Technician Interface 3-6
3.9 Key Switch 3-6
3.10 Keypad 3-6
3.1 1 Display 3-6
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3.12 Dual Signal Processor 3-7
3.12.1 Signal Processing Module 3-7
3.12.2 Bandwidth 3-7
3.12.3 Input 3-7
3.12.4 Signal Outputs 3-7
3.12.5 Alarm Outputs 3-8
3.13 General Operations 3-9
3.14 Filters 3-9
3.15 Identification 3-9
3.16 Dual Signal Processor Module Specifications 3 -10
3.17 Control Module 3 -11
3.17.1 Electronic Specs 3 -11
3.18 Enclosure 3 -11
3.18.1 Rear Panel 3 -11
3.19 Airborne Sensor/Preamp 3 -12
3.19.1 Electrical 3 -12
3.19.1.1 Preamp with specifications 3 -12
3.19.2 Environment 3 -12
3.19.2.1 Sensor with specifications 3 -12
3.20 Direct Coupled Sensor/Preamp 3 -13
3.20.1 Electrical 3 -13
3.20.2 Environment 3 -13
3.21 Dual Signal Processor Module 3 -15
3.21.1 Mechanical 3 - 15
3.21.2 Electrical 3-15
3.21.2.1 Amplifier (each channel) 3 -15
3.21.2.2 Filters (each channel) 3 -16
3.21.2.3 RMS Detector (each channel) 3 -16
3.21.2.4 Microcontroller 3 -16
3.21.2.5 Algorithm 3 -16
3.21.2.6 Front Panel I/O and Indicators 3 -17
3.21.2.7 Rear Panel I/O 3 -18
3.21.3 Environment 3 -18
3.22 Control Module 3 -19
3.22.1 Mechanical 3 -19
3.22.2 Electrical 3 -19
3.22.2.1 Algorithms 3 -19
3.22.2.2 Front Panel 3 -20
3.22.2.3 Rear Panel 3 -20
3.22.3 Environment 3 -20
3.23 Enclosure 3 -21
3.23.1 Mechanical 3 -21
3.23.2 Electrical 3 -21
3.23.3 System Environment 3 -21

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CHAPTER 4 ACOUSTIC LEAK LOCATOR SYSTEM
AIRBORNE INSTALLATION INSTRUCTIONS

4.1 Airborne Waveguide 4-2

Diagram of Airborne Waveguide Installation (Figure 4.1) 4-3
4.1.1 Mounting Procedure 4-4
4.1.2 Preamplifier Installation 4-6

CHAPTER 5 ACOUSTIC LEAK LOCATOR SYSTEM

STRUCTURE BORNE INSTALLATION INSTRUCTIONS

5.1 Structure Borne Waveguide 5 -2

5.1.1 Structure Borne Waveguide Installation 5-2
5.2 Structure Borne System Sensor/Low Noise Cable/Preamplifier 5-4
5.3 Feedwater Heater Sensor Installation 5-6

CHAPTER 6 ACOUSTIC LEAK LOCATOR SYSTEM INITIAL START UP

6.1 ALL System Electrical Connections 6-2

6.2 Supplying Power to System 6-3
6.3 System Adjustments 6-3
6.4 Control Unit Operator Interface - Version 3 6-4
6.4.1 Keys and Switches 6-4
6.4.2 Key Functions 6-5
6.4.3 Keypad 6-8
6.4.3.1 Channel Setup 6-9
6.4.4 Display Examples 6 -11
6.4.4.1 Display #1 (The default display) 6 -11
6.4.4.2 Display #2 (in set mode only) 6 -11
6.4.4.3 Display #3 6 -11
6.4.4.4 Display #4 6 -12
6.4.4.5 Display #5 (in set mode only) 6 -12
6.4.4.6 Display #6 6 -12
APPENDIX A FIGURES OF SYSTEM COMPONENTS

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 PREFACE

The ALL™ Acoustic Leak Locator is a leak detection system engineered to operate in
the harsh environments at utility and industrial boiler sites.
The system is modular and is adaptable to a variety of conditions which are typical at
such boilers.

Personnel who are responsible for installation, initial setup or routine operation and
maintenance of the ALL™ system should read this manual.

Chapter 1
INTRODUCTION, is an overview or the features of the ALL™ system.

Chapter 2
SYSTEM DESCRIPTION, is a detailed run down of the ALL™ system components.

Chapter 3
SYSTEM SPECIFICATIONS, is a list of technical specifications for the various
components associated with the ALL™ system.

Chapter 4
AIRBORNE INSTALLATION INSTRUCTIONS, explains how to stage the ALL
system for airborne applications.

Chapter 5
STRUCTURE BORNE INSTALLATION INSTRUCTIONS, explains how to
stage the ALL system for structure-borne applications.

Chapter 6
INITIAL START UP, shows how to use the operator control keypad on the system
enclosure. Menu-driven entry permits initial system setup and subsequent system su-
pervision.

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The story of Acoustic Monitoring International began in 1982, when Babcock
and Wilcox developed sensors for leak detection for high-pressure boilers. After
unsatisfactory results in trying to re-apply existing technologies to steam boilers,
B&W contracted with Hartford Steam
Boiler Inspection Technologies to design a
special system to their particular
specifications. HSBIT's Micheal R. Shaw
was given the task of designing the
system—the ALL™ Acoustic Leak
Locator.
After the initial installation of the ALL™
system at Alabama Power’s Gaston
Station in 1991, B&W purchased HSBIT,
and created TotalSCOPE Products and
Services for boiler operating efficiency. Micheal R. Shaw moved to Babcock &
Wilcox at this time to continue his work with the ALL™ system.
In 1997, B&W sold the assets of the ALL™ System to Micheal R. Shaw, and
Acoustic Monitoring International, Inc. was born.
AMI immediately began servicing units all over the world that were under B&W’s
warranty, and continues to provide parts for all existing systems.
Since its inception, Acoustic Monitoring International has established over 35
new installations of the ALL™ system. With over 2,000 sensors in service in
over 10 different countries, AMI's ALL™ system has been thoroughly field-
tested and is extremely reliable. AMI is constantly improving the system; the
Acoustic Leak Locator is in its fourth generation.

Acoustic Monitoring International, Inc.--Listening is our business.

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 Technical Support
Listening is our business.

Phone (330) 305-1422

E-Mail tech@acousticmonitoring.com

Fax (330) 494-9822

Postal 6707 Harbor Dr. NW

Address Canton, OH 44718

AMI Technical Services

• One-day installation training
• Unlimited life-time telephone technical
assistance
• Available setup / maintenance / operation
training, and installation inspection
• Warrantee for 18 months from date of shipment
or 13 months from date of installation
• Exchange Repair Service--we troubleshoot
down to what component needs repaired, and
can ship an exchange component overnight to

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 Chapter 1
INTRODUCTION

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1.1 Introduction
The Acoustic Leak Locator ®(ALL) system from Acoustic Monitoring International, Inc. is a
state-of-the-art leak detection and warning system designed for online monitoring of pressurized
systems and valves in the industrial environment. Its modular design, modern microprocessor
controls, and flexible I/O options make it readily suitable for a variety of leak monitoring
applications.

The ALL detection technology is based on high-frequency acoustic emissions emanating from
sites of gas or fluid leakage through orifices, cracks, and corrosion in pressurized systems.
Sensitive piezoelectric sensors mounted to the structure transform these acoustic waves to
electronic voltage signals, which are amplified, filtered, and processed to determine energy
content. The signal output is monitored continuously on each channel, and two alarm levels can
be defined independently by channel for system response. Figure 1.1 depicts various
configuration options available in the system.

Figure 1.1 Typical ALL™ System Layout

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 1.1.1 System Features

· Airborne, structure-borne, and combined applications are possible

· Modular design - 2 to 16 channels per enclosure
· Dual Signal Processing Modules
· Microprocessor Control in each module
· Programmable gain of 60dB in 2dB steps
· Bandwidth from 1KHz to 500KHz, unfiltered Figure 1.2
Front of ALL™ Unit
· Jumper-selectable airborne/structure-borne filter range
· Continuous root-mean-square (RMS) signal processing on each channel
· Programmable HI and LO alarm thresholds and delays for each channel
· Solid-state alarm output relays (optional)
· 4-20 mA or 0-16 mA analog outputs for each channel. For use on plant DCS
· All microprocessor boards are durable yet designed for easy replacement in minutes
· Local keypad or remote Personal Computer (PC) control of parameter settings
· Key-lock protection of parameter settings
· Parameter settings are retained after power loss
· RS-232 serial I/O communication
· TCP/IP converter optional
· All modules are bus-connected for ease of troubleshooting Figure 1.3
· Rackmount or benchtop enclosure option Back of ALL™ Unit

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1.1.2 System Overview

1.1.2.1 Hardware
The standard ALL configuration consists of several plug-in modules that reside on the system
bus:

1. The Dual Signal Processor Module (DSPM) are dual-channel modules that provide
signal conditioning, programmable gain, filtering, and signal measurement. Each DSPM
contains an HC-11 8-bit microprocessor with nonvolatile memory for storing channel
setup parameters (gain, HI/LO alarm settings and delays) and buffering measured signal
outputs.

2. The Relay I/O Units are dual-channel modules that provide signal input to the system,
and contain the alarm and processed signal outputs. One relay I/O is required for each
DSPM.

3. The Control Unit is required for each system for setup and testing of individual channel
controls. It has key lock system controls for setup access, operator keypad, and a two-line
backlit LCD display. An HC-11 microprocessor controls setup of the DSPM, interrogates
and reports channel status, and provides serial communications to an offline computer
through the serial I/O unit.

4. The Power Unit is a plug-in module that provides power to the system, and has a stan-
dard 3-prong AC input connector with replaceable fuse and configurable 110V or 220V
power.

5. The Serial I/O Unit is a plug-in module with a 25-pin serial I/O connector for external
computer communications and control. Both RS232 and RS422 asynchronous communi-
cation are supported. The serial I/O unit also has a group alarm output connector.

6. The Backplane is passive, and all modules plug into it from the front or rear, into VME-
style 64-pin connectors. This eliminates internal wiring in the system and provides ease
of maintenance and hardware configuration. Each enclose can accommodate up to 16
channels of signal processing and a control unit. Rack mounting or desktop configura-
tions are available. Front, rear, and side cut-away views of the ALL system are shown in
Figures 1, 2, and 3.

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1.1.2.2 Software

The ALL Control Unit provides local operator control of all system functions. A
key-lock control provides access to setup commands for system security. The
operator has control over the following system functions when the keylock is in
the SET mode. The ALL easily expands to handle larger monitoring applica-
tions. Each control unit can address up to 30 channels in two system enclo-
sures, and up to 255 control units can be addressed through the serial I/O inter-
face.

1. Channel Gain. Each channel gain can be adjusted from 2 dB to 60 dB

in 2 dB increments. In addition to the normal 60 dB of preamplifier gain,
this allows up to 120 dB of signal amplification in the system.

2. HI/LO Alarms. Each channel can be assigned two alarm levels between
0- 5 v ol ts (RMS) in 0.01 increments. Both alarm levels latch output
relays when the delay times have been exceeded. The HI alarm LED
is activated when the RMS signal exceeds the HI alarm setting. The LO
alarm LED is activated when the signal falls below the LO alarm setting.

3. Alarm Delays. Each alarm level can be assigned a time delay between
one second and 59 minutes 59 seconds in one second increments.
The measured RMS output must remain outside the alarm level continu-
ously during the delay period in order to latch the alarm relays.

4. Enable/Disable. Each channel can be individually enabled or disabled

within the system without changing other settings.

5. System Tests. The operator can activate two different test sequences.
One checks the proper functioning of the control unit and each of the
DSPM's, and reports the results. The second does the same but also
latches the HI/LO alarm relays to insure their proper function.

6. Alarm Reset. Allows the operator to reset the latched alarm conditions
on all channels.

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 1.1.2.3 Sensors and Preamplifiers

A complete range of sensors and frequencies is available for a wide range of leak monitoring
applications, including airborne and structure borne sensor mountings. Airborne sensors that are
available include hermetically-sealed low frequency (1-20 KHz), and low ultrasonic (40 KHz)
models. Structure borne sensors include 60,150, and 300 KHz models. The structure borne sensors
are available in integral preamplifier designs (40 dB), or with separate preamplifiers.

Housed in a conduit box between the sensor/waveguide and the Acoustic Leak Locator system,
the ALL™ Preamplifier provides the first stage of signal conditioning. An operating boiler with no
leaks has a characteristic low frequency (1 kHz) rumbling sound due to combustion noise. The
sound level is typically quite high. To improve the signal to noise ratio of the system, the ALL™
preamplifier is designed to filter acoustic frequencies below 1 kHz and amplify acoustic frequen-
cies above 1 kHz. Up to 90% of the acoustic signal present is eliminated. This allows the Acoustic
Leak Locator system to be set to higher sensitivities for leak detection.

Figure 1.4

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1.2 Computer and Software Overview
The signal is sent into the self-contained Acoustic Leak Locator (ALL™) system where
acoustic signal amplification and signal conditioning is completed for suitable processing.
The ALL™ system’s Dual Signal Processing Unit receives the analog acoustic activity sig-
nal, processes it and compares it to preset levels and timing parameters. The results are
available to the plant’s existing computer system in your required format (as 4-20 mA signal
level, alarm relays, and RS232 serial i/o) for graphic display and alarms.

ALL™ provides all the data needed for a clear and accessible visual display of acoustic
activity. Levels of alert are predetermined, so that when there is a significant change in ac-
tivity on any channel you can know a leak has occurred.

Figure 1.5
Display Options

1-7
1.3 Airborne Acoustic Activity Monitor System Overview (Option C or
D of Figure 1-1)
To sense the sound in a boiler, the System uses acoustic sensors mounted on the ends of
waveguides (Figure 1.6). The waveguides are mounted on boiler access doors, observation
doors, or unused soot blowers ports. The waveguide provides a smooth continuous acoustic path
to the sensor and provides thermal protection by eliminating the direct radiant heat of combustion
that could overheat the sensor. A secondary purpose of the waveguide is to prevent flyash or
wash water from directly contacting the sensor diaphragm. The waveguides are either welded
directly to a door or attached with a special fixture and oriented to place the acoustic sensors in
as nearly a vertical position as possible.

Figure 1.6

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When a pressurized fluid such as steam or water escapes through a hole in a tube, it generates
sound in the 3 kHz range due to the interaction of a high velocity stream mixing with a sur-
rounding medium such as flue gas in a boiler. The onset and growth of a leak can be slow or
rapid depending on the failure mechanism involved. In either case, the sound level in a charac-
teristic range of frequencies increases by a factor of 2 to 500 or more.

An operating boiler with no leaks has a characteristic low frequency (1 kHz) rumbling sound
due to combustion noise. The sound level is typically quite high. To improve the signal to noise
ratio of the system, preamplifiers (Figures 1.4 through 1.6) are designed to filter acoustic fre-
quencies below 1 kHz and amplify acoustic frequencies above 1 kHz; otherwise, the normal
operation low frequency signals would saturate the Acoustic Leak Locator. The Acoustic Leak
Locator provides additional acoustic signal amplification and signal conditioning to provide
suitable inputs for the computer.

The system is designed to monitor the interior acoustic environment of an operating boiler. An
audible alarm is triggered when the sound level in a present frequency range rises above a pre-
determined level.

1 -9
1.4 Structure Borne Acoustic Activity Monitor System
When a pressurized fluid such as steam or water escapes through a leak in piping, valves, or
feedwater tubes, it generates acoustic emissions which travel through the component's struc-
ture. Small holes generate high frequency acoustic emissions (above the audio frequency range)
as the hole increases in size the low frequency complement of the acoustic emission increase
and the airborne noise can be heard. To detect the acoustic emissions early, the structure borne
waveguide as shown in Figure 1.7 is connected to the component to be monitored. The
waveguide serves two functions; (1) it couples the acoustic emissions from the component to
the sensing device and (2) it protects the electronic sensing device from the high temperature of
the component being monitored. The sensing device is a piezoelectric crystal with a resonant
frequency between 150 and 300 kHz, which converts the acoustic emission signals to low en-
ergy electrical signals. A preamplifier is installed near each sensing device to filter out un-
wanted signals and amplify the desired acoustic emission signals to a suitable level which will
allow transmission of the signal to the central monitoring location.

The ALL System provides acoustic emission signal conditioning to provide suitable inputs for computer
processing. The ALL system may also be used as a stand alone system.

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