Industrial Equipment Built to LastTubular Air Pre-heater Inspection, Repair, and Rebuilds
Corrosion Monitoring Services, Inc. (CMS) has been helping customers assess, monitor, and repair air heaters
since 1982. In fact, CMS has repaired or rebuilt thousands of tubular air pre-heaters (APH) in North America
and overseas. In the process, the company has established a reputation for delivering quality products and
services on-time and on-budget.
CMS has significantly advanced APH technology by developing patented and proprietary solutions that
significantly improve equipment performance and service life. Analysis data proves that under-performing
air heaters can negatively affect other important parts of your operation. This equipment includes gas and
air fans, bag houses, precipitators and scrubbers that depend on the APH units to deliver preheated air
within a specific pressure, volume and temperature range.
Today, CMS is the only company in the world that offers complete, performance assessment, integrated
corrosion assessment and repair services for tubular air pre-heaters. Our inspection and assessment programs
provide an accurate and comprehensive picture of the entire air heater system, pinpointing all areas of tube
damage and potential financial impacts.
Our experienced inspection specialists start the process
using custom-designed tools to inspect your equipment
and look for damage that affects your daily performance
and sometimes leads to unscheduled downtime. In addition,
we have developed a proprietary Air Leakage Calculator
(a unique software tool) that uses your own operating data
to determine precisely where your system performance is
impacted and what you are losing in the process. This
approach has saved our customers millions of dollars
and helped them realize payback in as little as a few months.
CMS stocks over a million linear feet of steel at
our climate controlled warehouse and ready to
respond to your needs at a moments notice.
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CMS offers cutting-edge solutions installed
with proprietary tools and patented systems
operated by the industries’ most experienced
team of professionals.
“�All�work�went�very�smoothly�from�the�pre-planned�set-up�to�execution�and�demobilization�and�final�walk�through�with�owner�representatives.�The�CMS�work�flow�was�like�a�well-oiled�machine.�It�is�apparent�that�CMS has a commitment from top-down leadership to emphasize safety, specialized work force, and great project execution. CMS delivered all they committed to deliver and within the time frame agreed to.” — Jack I. Williams, Project Engineer, WestRock
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CMS Services a Broad Spectrum of Industries
Customers in a wide variety of industries call on CMS, whether they need emergency service or have long-range
plans to improve operations. Working with different companies in difficult and unique operating environments
has exposed our teams to the wide variety of challenges faced by different configurations in all types of thermal
plants. Some of the solutions to those often difficult problems are applicable across industry sectors. We take
pride in using our experience to your advantage.
BIO PROCESSING (1)
CEMENT (2)
CHEMICAL PROCESSING (3)
COAL POWER (4)
FOOD PROCESSING (5)
PULP & PAPER (6)
WATER ENERGY (7)
1
3
2
4
765
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Cascading Problems Corrode Your Operating EfficiencyInstalling mechanical plugs to isolate damaged air heater tubes is one short-term strategy for regaining
at least some of your fan and boiler capacity and slowing down and the development of new tube failures.
However, it’s important to realize that something is causing tubes to fail and that the damage mechanisms
will still be at work even after the plugs are installed. Those problems are often cascading in nature, causing
hidden inefficiencies and other issues not just in your APH, but throughout the process.
Here are just a few facts about damaged air heaters and how they might be costing you efficiency and
corroding your profits:
External Corrosion, Air Side Dew Point CorrosionABS Corrosion
• A 2009 EPA study reported that just a 40˚F
increase in outlet APH temperature results
in a 1% reduction in net boiler efficiency.
• A 1% boiler efficiency penalty is commonly
observed where just 12% air leakage has
developed. Fly-ash based fouling or
mechanically plugged tubes can result
in similar performance impacts.
• Tubular air heater leakage can account for as
much as 25% of total fan horsepower, not only
using more energy, but decreasing the life
expectancy of the fan and motor.
• Leaking air heaters increase emissions and
reduce the effectiveness of downstream
pollution control equipment because of
increased fuel and gas flow.
• One problem leads to another, as temporarily
repaired APH units actually decrease the surface
area for heat transfer and thus the temperature
of combustion air, while increasing gas outlet
temperature, pressure drop and net fuel
consumption.
• In many cases, boiler operators are forced to
de-rate their plants due precisely to air heater
leakage and fouling. Statistics from the NERC
GADS database demonstrate that between
2007 and 2011 a total of 3,233,636 MWH of
forced de-rates were due to “Combustion
Air & Gas Causes”.
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CMS Delivers Solutions You Can Depend OnCMS has spent decades focusing on customer needs and working with them to develop solutions that get them
back up and running quickly. From preliminary inspection to on-time delivery, we have developed competitive
advantages that we apply to the benefit of our customers. Here are just a few of the advantages CMS offers:
Planning Fabrication
• Air Pre-Heater Calculator (applied to
“as found” and “follow-up” monitoring
performance) to assist in quantifying the
real value of performance
• Root-cause analysis capabilities to select
the best option for repairs
• Financial impact reporting for repair option
determination and budgeting decisions
• Financial impact reporting detailing energy
savings and emission reduction estimates (e.g.:
mercury, ash, CO, CO2, SO2, SO3 emissions)
• Corrosion/erosion resistant tubular
air-pre Heater components
• One-stop shop fabrication facilities, eliminating
third party supplier risks and costs
• Exclusive distributor of CR50TM tubing,
stocked and available for quick-shipping
and emergency repairs
• Exclusive distributor of corrosion resistant
internally rifled tubing that can provide
significant heat rate improvements in
horizontal tubular air heaters.
• Pre-assembled tubing options for in-situ repairs
enable rebuilding of critical equipment without
costly displacement of surrounding structures.
Safe, On-time Installation Guaranteed Performance
• Rapid Repair™ Conveyer System
• Mobilization ready repair response systems
that can be on the way to our customers
quickly in emergency situations
• OSHA Sharp perfect score
• Rescue-training confined
space attendants (NFPA
1007 & 1670 certified)
• Extended service life of tubular air pre-heaters
• Air-Tight™ Quality Assurance
• Five-year Convective Tube Solution™ warranty
(our bottom line for reliability, backed by CMS)
• Five-year EROS warranty covering fly ash
erosion failures
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Built to Last
CMS replaced all tubing in the CSWS RRF facility’s Unit 11 and 13 air
heaters with corrosion resistant CR50 alloy and Convective Tube Solution.
Performance of the boilers improved immediately. The custom repair
resulted in several other notable gains, including fans, pollutions control
and bag house performance. The overhaul resolved the chronic and rapid
failures that damaged each of the units over many years.
“ When CMS comes to the site, they have a crew that’s very professional. Their foremen have been top notch compared to other�contractors�that�are�out�there.�I’ve�been�around�a�long�time,�and they have an excellent workforce.” — John O’Rourke, Plant Manager, CSWS RRF, Hartford, CT
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The CMS team has hundreds of years combined on-site experience
solving customer problems with custom solutions that enhance
operating efficiency. President Alex Turner (center, row two) stands
behind the company with the top safety record in the business!
Air Heater Repair Services to Fit Your NeedsCMS offers the industry’s widest variety of solutions for APH repair and replacement. We develop a solution that
fits your own unique requirements. On request, our experienced team can quickly help you evaluate your needs
based on site inspection and data analysis, using our proprietary Air Leakage Calculator. We can then tailor a
solution to improve your operation, including partial tube repair, in-situ repair, Convective Tube Solution™, CMS
Eros™ as well as other options.
Our goal is to get you back up and running to maximum efficiency as quickly as possible, so that you are able
to realize measurable improvements immediately. We also work hand-in-glove with your management team to
develop strategies that reduce associated costs required to complete necessary repairs.
“ You get technology that is going to give you performance and service life that doesn’t exist otherwise. We can often tailor our repairs to the exact damage mechanisms that are occurring.” — Alex Turner,
President, CMS
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CMS in action on the job site. Our team of professionals have repaired and/or
rebuilt hundreds of air heaters in the field, often in tight turnaround timeframes.
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PARTIAL TUBE REPAIRIn many cases, damage to air heater tubes is localized and limited to one section of the tube. This is especially
true when erosion is the primary damage mechanism and failures are located close to the tubesheet plate.
When local damage is identified, CMS frequently recommends partial tube repairs of the air heater.
In a partial tube repair, CMS removes only the damaged section of the tube and installs structurally secure,
air-tight replacement tubes, using its specialty tooling and custom pre-fabricated couplers. This method
preserves the undamaged section of the tube and is often as effective as a full-length re-tube, but a fraction
of the cost. Since 1985, CMS has performed thousands of partial tube repairs and is the industry’s leading
provider of this solution.
Benefits of partial tube repair include:
• Addresses root cause of damage
• Scope can be performed in short outages
• Enables air heater repair without removing surrounding structures
• Minimal scaffolding
• Crane rental not required
• Warrantied seal between parent and replacement tubing
• Material or design upgrades available
Since 1985, we have performed more partial air heater repairs than anyone in North America.
Air Heater Repair Services to Fit Your Needs
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IN-SITU REPAIR Access to an air heater is frequently limited by overhead obstructions or
the location of adjacent equipment, such as economizers or dust collectors.
In many cases, these obstructions make it difficult, if not impossible, to install
full length replacement materials, without taking an extended outage.
CMS developed the in situ method of repair, allowing tubular air heaters to be
rebuilt from the inside out, without removing any of the surrounding structure.
Throughout its projects, CMS uses Rapid Repair™ Conveyer Systems that have
been custom designed for the sole purpose of rebuilding tubular air heaters. These proprietary tools allow for
major repair projects to be performed in a faction of the time that would otherwise be required.
The goal is minimal disruption of your ongoing operations, enabling a rapid return to full capacity, but with much
improved efficiency. In addition to saving you time, the in-situ process significantly reduces associated costs and
schedule for the repair by minimizing the need for scaffolding and crane procurement. We plan and execute our
work within your footprint!
CMS’s turnkey repair process begins months in advance, when we fabricate materials in our own shop. We don’t
rely on third-party sources, which maximizes our quality control, minimizes costs, and reduces lead times, all are
time-proven benefits that we pass on to our customers.
Our experienced project managers and engineers work with you to determine the best possible solution that
allows for seamless installation during an outage. We stand by our products and services, backing them with
expert service, and in some cases, a five-year warranty.
Benefits of in-situ repair include:
“�We�have�a�CFB�boiler�with�a�tubular�air�pre�heater.�CMS�replaced�the�first�pass�of�each�the�SA�and�PA� air heaters in our plant in 2009. They replaced the air heater sections in a timely manner without any safety incidents.
“ We now have a tight air heater that performs great and the Corten® material proved to hold up to the�cold�end�corrosion�we�were�experiencing�prior�to�2009.�I�would�recommend�them�to�anyone� desiring to have this type of work performed. They have successfully enhanced their QC program and their safety standards are world class.” — Dan Twigg, Boiler Team Leader here at AES Warrior Run Power Plant in Cumberland, MD
Air Heater Repair Services to Fit Your Needs
• Rapid repair scheduling and mobilization
• Performed safely and efficiently within
you footprint
• Custom solution, rather than a
“one-size-fits-all” approach
• Warrantied repairs (in some cases)
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CONVECTIVE TUBE SOLUTION™The CMS Convective Tube Solution™ is the tubular air heater industry’s first and only long term solution
to aggressive dew point corrosion damage. Cold-end corrosion, localized cold spots, and heat sinks in an
air heater can have devastating effects on operating and, ultimately, your financial performance. Damage
develops when the surface temperature of tubing drops below the acid dew point. Acid condensation often
leads to losses in wall thickness. Failure rates vary, depending on the fuel source and boiler configuration,
but ongoing corrosion, plugging, and other issues that affect APH performance can have the following
damaging impacts on an operation.
The patent pending Convective Tube Solution™ is a product of precision engineering and more than 30
years of experience inspecting and repairing tubular air heaters. During the repair, CMS upgrades the metallurgy
of the tubing. Modifications to the design of the tube and tubesheet plate are performed during field installation.
Repairs result in the effective elimination of dew point corrosion failures and fly ash plugging. A few of the many
benefits that come with CMS’s Convective Tube Solution™ include:
A rapid return on investment: By eliminating cold-end corrosion,
the CMS Convective Tube Solution™ significantly reduces net fuel
consumption and parasitic losses. At no cost to customers, CMS
can use its proprietary Air Leakage Calculator to provide a thorough
analysis showing the financial impact of an APH’s current condition
and an estimated return on investment timeline for repairs.
Customers have achieved payback in as little six months and are
realizing significant ongoing savings. Examples of the calculator
and analysis can be provided on request.
Air Heater Repair Services to Fit Your Needs
• Reduces surface area available for heat transfer
• Lowers boiler efficiency
• Increases pressure drop
• Increases fan and emissions equipment
energy requirements
• Damages/wears ancillary equipment
and infrastructure
• Reduces downstream pollution control
performance
• Unit steam capacity and generation restrictions
• Reduces dew point corrosion and increases
life expectancy 3X minimum average
• Significantly diminishes cold-end ash fouling
and reduces or eliminates washing
• Improves air heater and system performance
• Helps reduce wear on ancillary equipment
• Reduce excess energy consumed plant-wide
• Includes a 5-year warranty against dew point
corrosion and fly ash fouling. This added
benefit includes annual inspections and
condition assessments performed at no charge.
CMS Convective Tube eliminates cold-end corrosion.
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CMS EROS™ The EROS™ is a CMS Inc. patent-pending design that provides long term relief from problems associated with
fly ash erosion. Fly ash erosion often occurs within the first 3-5 inches at the gas inlet of the tube up to the top
tubesheet plate. In an EROS™ repair, CMS removes only the damaged area of the equipment and upgrades the
design and metallurgy of the replacement material to prevent reoccurrence of damage. The EROS™ design also
ensures that wear damage occurs to the sacrificial areas only (overlay plate and sleeves).
An EROS® repair project provides you with the following benefits:
• Upgraded metallurgy at the area most vulnerable to erosion damage
• No increase in air heater pressure drop
• EROS® specially hardened inserts can be joined to undamaged sections of tubing
• Significantly reduces long-term maintenance costs
• Includes an air heater preventive maintenance program
• Includes an optional 5-year warranty against erosion failures
HERO™ APH EXTERNAL CORROSION GUARDSPart of our ongoing development of the Hero™ APH,
our CMS patent-pending
external corrosion guards provide an extra measure of protection
against water damage to your air heater. Our external corrosion
guards can be installed above the bottom of tubesheet plate or
above the baffle level, depending on customer requirements. This
small but important feature, delivers big benefits, including:
• Pre-fabricated in advance of repair, leading to ease of installation
• Provides sacrificial steel to protect tube outer diameter at
BTS and anti-vibration baffles
• Significantly extends service life of replacement tubing
Air Heater Repair Services to Fit Your Needs
CMS’s patent-pending corrosion guards provide
some insurance against potential water damage.
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AIR LEAKAGE CALCULATORIs your Air Pre-heater corroding your profit margins? More importantly, when the air heater degradation
begins, failure is not a linear process. A failed leaking tube may bring a zone near the tube below the acid
dew point creating failures all around. The CMS proprietary Air Leakage Calculator enables you to pinpoint
problems in your system that are costing you money. Our unique software, which took years to develop, will
pass performance related audits utilizing ASME type boiler and air heater calculations. The calculator analyzes
boiler efficiency, air heater leakage, impacts to auxiliary power. The evaluation assesses impacts to emissions
and associated equipment operating cost and cost of materials purchases and disposal. In addition, our energy
calculator can even be used to estimate energy savings and reduction in emissions.
Once a unit model is created, a follow-up analysis can be performed at any time with little effort. You can track the
unit and air heater performance over time with little effort. All it takes is a phone call and a download file of the
previously selected process data.
Some APHs begin leaking the moment they go online. Using our calculator, we have measured leakage
>50% in some units. Our unique monitoring is able to factor out the impacts on performance due to cooling
water variations and weather changes which impact both turbine and fan performance.
After the initial analysis, we are able to continue monitoring your system and can provide periodic reports
on request. A follow-up analysis requires little effort from site and CMS because the model has already been
established and tested. And our analysis comes complete with a nondisclosure agreement to protect your
proprietary in-house data.
Air Heater Repair Services to Fit Your Needs
CMS’s air heater calculator can pinpoint problems in your APH and other parts of your operation.
Corrosion and plugging (as shown here) often leads to cascading problems up- and down-stream
that impact your company’s bottom line. CMS uses the industry’s most analytical tools to help you
select the right repair or replacement option that meets your budget and operating requirements.
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130
135
140
145
150
155
160
165
170
Net
Po
wer
Pro
du
ced
FD
Fan
Air
Flo
w
Blue = Airflow
Red = Net Power MW
1200
1250
1300
1350
1400
1450
1500
1550
Performance analysis may include review of historical data as shown above. In this case, the increase in leakage
is seen in the flow from the forced draft fan. As the leakage increases, the net generation decreases. This is one
example of hidden inefficiencies in your operating system, providing you with knowledge that puts you back in
control, so that you can quickly assess and repair damaged equipment.
Air Heater Repair Services to Fit Your Needs
Example Case 1 Example Case 2 VALUES USED IN DISCOUNTED CASH FLOW ANALYSIS
-37,777 -67,723 (67,723)
-108,574 -109,571 (109,571)
-20,979 -20,979 (20,979)
-342,144 -342,144 (342,144)
-263,247 -263,247 (263,247)
-772,720 -803,664 (803,664)TOTAL CASH FLOW IMPACT Based on current condition
Based on current conditionGross margin loss due to increase in station service
Based on current conditionGross margin loss due to reduction in plant output
Due to increase in emission control consumables: Based on current condition
Fuel Cost due to increase in station service: Based on current condition
ITEMIZED LIST OF FINANCIAL IMPACTS
CASH FLOW IMPACT BASIS
Fuel Cost due to loss of boiler efficiency: Based on current condition
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Air Heater Repair Benefits
A repaired or rebuilt air heater, using CMS
patent-pending designs and corrosion resistant
tubing, can extend the life of your APH and other
critical equipment.
Environmental
A damaged air pre-heater is a liability that can cost you more than system efficiency and bottom-line profits.
By eliminating air leakage and returning the air pre-heater to ‘as built’ condition with improved materials for
erosion and corrosion protection, Corrosion Monitoring Services has helped boiler operators across the United
States achieve and exceed their environmental objectives and operate at MAXIMUM operational efficiency.
CMS works to ensure that your APH performs as designed and helps keep you operating safely within
applicable regulatory requirements.
The detrimental effects of a corroded air pre-heater can lead to environmental issues. Don’t let these
potential problems compromise your operation:
• Increased waste water
• Disposal of excess fly ash due to increased fuel demands
• Emissions of mercury, CO, CO2 , SO2 , and SO3
• Excess auxiliary power to operate fans required to move the air leakage and provide sufficient
flow through plugged tubes
• Increased use of additives needed to keep a treat the additional fuel for system operational
• Potential for forced outages and catastrophic failure of the unit or equipment
An often neglected system, the air pre-heater serves
an essential role in the efficiency of the boiler system
and in the pollution control process. At CMS, we
have significantly advanced the technology, under-
standing, and approach for the inspection and repair
of these systems.
Regardless of the industry, CMS provides
long term operational solutions that protect
air pre-heaters from erosion, corrosion, and fly
ash fouling. Our inspection and repair solutions
have helped hundreds of utilities, pulp and paper
mills and other processing plants optimize their
operational efficiency, regain capacity, and improve
the performance of their pollution control systems.
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In many cases, our customers have delayed repairs until operational impacts are already a significant problem.
Usually at that time the rate of deterioration is advanced and cannot be ignored. Our calculator can determine
this in advance before leakage becomes a derating of operating requirements.
Since the fan curve is shifted due to molecular weight of diluted gas and ambient conditions, this unit is derated
at times during summer months. The cost easily justifies repairs.
Financial
The cumulative financial impact of air heater efficiency is rarely adequately measured or observed,
but the results speak for themselves. By eliminating leakage in the system, plants can realize up to
a 4% reduction in net fuel consumption.
Not only do improvements to your APH units cut overall energy consumption, but they should help reduce
your maintenance and waste disposal costs. If the boiler is the heart of your operation, then the air pre-heaters
are its lungs. Ultimately, repair should extend the APH units’ life and everything that they touches in your system,
from fans to boilers to pollution control equipment. 902 Equity Drive · St. Charles, IL 60174
T 800 637 6592 · F 630 762 9301 WWW.CMSINC.US
Plant Type Boiler Type Capacity Air Heater Configuration Estimated Change in Leakage (%)
Annual Cost Savings
Bio Mass Sub Traveling Grate 50 MW Two AH Two Air Streams 7.3% $1,290,000Bio Mass Sub Vibrating Grate Stoker 20 MW One AH 24.7% $4,940,000Bio Mass Sub Zurn Drum CFB 42 MW Two AH in Series 11.0% $790,000
Coal Super Wall Fired 960 MW One AH 6.7% $9,480,000Coal Sub PC B&W Wall Fired 180 MW One AH 27.0% $6,070,000Coal Sub B&W Wall Fired 655 MW 2 RAH & 1 TAH in Parallel 13.6% $1,860,000Coal Sub PC RS Wall Fired 180 MW One AH 23.2% $800,000Coal Sub FW CFB 47 MW One AH Two Air Streams 24.4% $720,000
Paper Mill Sub Traveling Grate 35 MW One AH 20.2% $820,000Paper Mill Sub FW CFB 17 MW One AH Two Air Streams 16.0% $1,260,000Paper Mill Sub B&W Stirling 52 MW One AH 27.6% $970,000Paper Mill Sub Traveling Grate Multiple One AH 21.0% $470,000Paper Mill Sub Stoker Boiler 5 MW One AH 25.0% $180,000
Refuse Sub Spreader Stoker 23 MW One AH 31.8% $1,187,218Refuse Sub Traveling Grate Stoker 34 MW One AH 38.0% $482,417
Note: Annual Cost Savings does not reflect cost of repair.Cost Factors: Contacts:
1) Loss of Boiler and Air Heater Efficency Lonnie A. Coffey (Thermal Analysis)2) Fuel for Auxiliary Power 865-806-1791 - [email protected]) Emission Control Consumables4) Revenue loss for increased Auxiliary Power Jack McKeegan (Financial Analysis)5) Revenue loss for reduced Generating Capacity 630-762-9300 - [email protected]
CMS AIR HEATER CALCULATOR RESULTS -- RECENT EXAMPLES
A proud member of the OSHASAFETY HEALTH ACHIEVEMENT
RECOGNITION PROGRAM
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Inspection Services Corrosion Monitoring Services, Inc. (CMS) has been helping customers identify, assess, repair and monitor air
heaters and other equipment since 1982. CMS offers a complete range of inspection services that not only
determine the exact extent of existing damage, but can also identify the root cause and its probable failure
rate so that you can proactively plan your next steps for a longer term solution.
Our inspectors use acoustic eye, pressure testing and other inspection equipment and techniques to isolate
corrosion and erosion damage in electric utility, refinery, chemical processing, pulp & paper, biomass and
waste-to-energy operations throughout North America.
Comprehensive assessment programs conducted by the industry’s most experienced APH inspectors provide
an accurate picture of air heaters and other critical equipment, pinpointing corrosion, fouling, and other damage
that hampers operations, drains energy, and dilutes profits.
After we complete any inspection, all of our findings and recommendations are detailed in an Executive Summary
Report. Depending on the type of inspection performed, the Executive Summary might include corrosion rate
charts, ultra-sonic readings, failure rate metrics, detailed tubesheet maps, and maintenance recommendations.
The thoroughness of a CMS inspection helps identify where your equipment is damaged and is the first
step toward ensuring that the condition of the air heater never compromises operational or pollution control
objectives. Meeting those important objectives starts and by hiring a contractor that has deciphered and
solved nearly every air heater problem you can imagine – an experienced team member you can depend on.
We offer a variety of inspection services to analyze the condition of your equipment and work with you to
determine the best course of action. Reliable diagnosis of the problem is the first step in the right direction.
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Agile Services to Meet Immediate NeedsCMS also offers its customers general mechanical maintenance services performed by our highly skilled
and trained staff. (See our list of common repair and inspection services below.) Because we are committed
to your bottom line, CMS blends mobilization charges, benefiting you by putting our onsite crews to work
on your equipment issues, without incurring additional mobilization charges.
INDUSTRIAL REPAIR & INSPECTION SERVICESInspect Repair
Air Heaters 3 3
Expansion Joints 3 3
Ash Hopper 3 3
Dust Collectors 3 3
Bag House 3 3
Condenser 3 3
Evaporator 3 3
Air and Gas Ducts 3 3
Stacks 3 3
Turning Vanes 3 3
High Angle Inspection 3 3
Augers 3 3
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CMS’s custom inspection trailers provide resources on-site, and facilitates on-time delivery of our products and services as well as troubleshooting to address unforeseen challenges. CMS maintains a fleet of fully equipped trailers to mobilize for in-situ repair and unit replacement projects.
ACOUSTIC EYE INSPECTIONCMS innovative acoustic eye inspection solution is
designed specifically for detecting faults commonly
found in industrial tube systems. These could include
leaks, increases in internal diameter caused by wall
loss, full or partial blockages, as well as other issues
that negatively impact your operations.
Using portable acoustic pulse reflectometry (APR)
equipment, CMS inspectors direct one-dimensional
acoustic waves at tubular systems to detect defects
in cross sectional areas of the tubing. If the pulse
encounters a discontinuity in cross section, a
reflection is created, and we are able to quickly
isolate problem areas. Once we’ve identified any
holes, blockages, or other issues in your air heater
or other equipment, we are able to repair those
systems and improve your operating efficiency.
HIGH ANGLE ROPE INSPECTIONCMS offers high angle rope access inspections
to assess difficult-to-reach or inaccessible areas.
During a high angle inspection, CMS provides
a highly trained inspector, who has also received
>80 hours of NFPA rope access training. In
addition to your air heater, our professionals
can inspect the condition of your ductwork,
casings, expansion joints, hoppers and chimneys.
Additional advantages of high angle rope access
inspections include:
• Many times more cost efficient than erecting
scaffolding to access hard-to-reach locations
• Identification of localized damage, which helps
customers avoid unexpected budget busters
caused by emergency repairs
• Detailed maps and reports to assist in planning
for future outages
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PRESSURE TESTING Pressure testing is an effective tool that can
be used to identify tube failures and determine
the overall health of an air heater. During this
procedure, a CMS inspector pressurizes each
tube and records air leakage rates as they occur
in damaged equipment.
When our inspectors identify failed tubes,
they remove them from service by installing
a mechanical plug at each end of the tube.
Removing a failed tube from service is a quick
way to improve boiler efficiency and reduce fan
energy. CMS recommends this option as a
temporary-only solution to get you back up
and running more efficiently.
INSPECTOR QUALIFICATIONS Our highly trained and skilled inspectors significantly
enhance quality control and help prevent costly
outages on equipment by evaluating wear and
internal degradation.
CMS inspectors are hand-picked and spend years in
training before leading any inspection. We provide
in-house seminars and training to ensure that our
inspectors recognize, understand, and respond to
each damage mechanism. Our staff communicates
with your team on a regular basis to help keep you
apprised of any significant findings that require im-
mediate attention.
After your inspection is complete, you will receive a
comprehensive executive summary that focuses on
the current condition of your air heater and the root
cause for its deterioration. You can rely on our many
years of experience to help ensure that you spend
capital wisely during future maintenance and select
a solution that is built to last.
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Safety FirstLike the customers in the industries CMS serves, we take safety seriously. CMS Safety Services are unique within
the industry. Most of our safety officers and confined space attendants are current or former firefighters with
decades of experience responding to confined space emergencies. We pride ourself in both the rigorous and
extensive training that our employees receive and the cutting edge equipment that we supply during outages.
On a daily basis, our Rescue Services Crews help our customers in a variety of capacities, providing standby
rescue services, high angle training, and confined space inventories. In fact, we provide complete outsourcing of
outage safety needs, including suppling all confined space attendants and safety officers to direct the outage.
Our safety record speaks for itself. In fact, CMS earned an OSHA SHARP perfect score. Although we work hard to
minimize risks, we are still able to meet your demanding inspection, repair, and replacement schedules in a timely
fashion. We just do it safely!
Confined Space Safety Services
CMS repair crews participate in comprehensive and specialized confined space safety training before they ever
work on a job site. In fact, we are the only tubular air heater inspection and repair contractor in the U.S. that offers
NFPA 1007 and 1670 worker-to-rescue training certification. All of our employees are Confined Space Rescue
Trained (NFPA 1670 and 1006, OSHA 29 CFR 1910.134, ANSI Z 117.1) and have received a minimum of 86 hours
of hands-on confined space rescue training using a full-scale permit-required confined space simulator.
CMS has taken an industry-leading approach to training and qualifying confined space attendants (CSAs).
After receiving a minimum of 86 hours training, each CSA is certified as an Emergency Rescue Technician (ERT).
The ERT training includes advanced confined space rescue techniques/operations, Incident Command System
(ICS), supplied air respirators (SAR), self-contained breathing apparatus (SCBA), rapid intervention team (RIT)
operations, complex patient packaging techniques, first-aid, CPR, and AED. Rescue training even includes
advanced high angle rope rescue techniques for complex operations. Many of our confined space attendants
are former or current firefighters, who have extensive rescue training and real-world experience.
Standby Rescue
Due to the level of training and rescue equipment brought to each job site by CMS, our working crew can double
as a standby rescue team. We can also augment plant or contractor safety needs that may arise during an outage.
Worker to Rescuer Training
CMS has developed a customized training program known as “worker-to-rescuer”. Completing the worker
to rescuer training program enables our employees to transition from their traditional roles as workers into
a fully qualified and competent team capable of responding to any confined space emergency.
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CMS employees receive extensive training in safety and rescue in our model air heater that simulates actual conditions.
Some employees are former or current firefighters, with extensive experience in handling emergencies.
“�CMS’s�safety�program�is�world�class�compared�to�others�that�I�see�in�the�industry.�They’ve�got�an�excel-lent�program,�and�they’re�a�contractor�that�I�wouldn’t�hesitate�to�do�business�with�again.�You�can�have�all�of the best equipment, but if you don’t have the best people to operate it, you’re not running optimally.” — John O’Rourke, Plant Manager, CSWS RRF, Hartford, CT
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SAFETY SERVICESStandby Rescue 3
Rescue Trained Confined Space Attendants 3
Consulting 3
Onsite Training 3
Confined Space Inventory 3
Equipment Rental 3
Safety Services 3
High Angle Inspection 3
Corrosion Monitoring Services, Inc.
902 Equity DriveSt. Charles, IL 60174
Phone : (630) 762-9300Fax : (630) 762-9301
www.cmsinc.us