Water leakage alarm system for heat exchanger

Abstract

The invention relates to the technical field of heat exchanger water leakage monitoring, and discloses a heat exchanger water leakage alarm system which comprises a first pipeline and a second pipeline, the adjacent ends of the first pipeline and the second pipeline are fixedly connected with pipe plates, the two pipe plates are fixedly connected, and alarm systems are arranged on the first pipeline and the second pipeline. Through collaborative analysis of parameters such as temperature, humidity, pressure and flow, the accuracy of leakage detection is remarkably improved, and misjudgment caused by fluctuation of a single parameter is avoided. In the data processing process, a multi-step processing mode of cleaning, filtering and formatting is adopted, so that the stability and reliability of the collected data are enhanced, and meanwhile, the recognition of abnormal signals is more efficient. In a threshold value analysis link, a dynamic adjustment and storage mechanism enables the system to adapt to different working condition changes, so that self-adaptive adjustment of threshold value setting is realized, and the probability of false alarm caused by fixed parameter setting is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of heat exchanger water leakage monitoring, in particular to a heat exchanger water leakage alarm system. Background Art

[0002] In industrial production and daily life, heat exchangers are common and important equipment, widely used in petrochemical, metallurgy, electricity, pharmaceutical and other fields. Its main function is to achieve energy transfer between different media through heat exchange. However, during the operation of the heat exchanger, water leakage may occur inside the heat exchanger due to equipment aging, material fatigue, changes in working conditions or improper operation. Water leakage will not only reduce the operating efficiency of the equipment, but may also cause equipment damage, production accidents, energy waste and even environmental pollution, seriously affecting the safety and economic benefits of production.

[0003] Traditional heat exchanger leakage detection methods mainly rely on manual inspections or simple sensor alarm systems. However, these methods have many limitations. For example, manual inspections require a lot of manpower and a long detection cycle, and cannot achieve real-time monitoring; traditional sensor alarm systems usually only rely on changes in a single parameter (such as pressure or flow) to determine leakage, which is easily affected by environmental interference or parameter fluctuations, and there is a risk of false alarms or missed alarms. At the same time, traditional methods are difficult to quickly locate the specific location of the leak, resulting in low efficiency in problem handling and maintenance. Summary of the invention

[0004] In view of the shortcomings of the prior art, the present invention provides a heat exchanger water leakage alarm system, which solves the problem that the traditional heat exchanger leakage detection method mainly relies on manual inspection or simple sensor alarm system. However, these methods have many limitations. For example, manual inspection requires a lot of manpower and a long detection cycle, and cannot achieve real-time monitoring; traditional sensor alarm systems usually only rely on changes in a single parameter (such as pressure or flow) to judge leakage, which is easily affected by environmental interference or parameter fluctuations, and there is a risk of false alarm or missed alarm. At the same time, it is difficult for traditional methods to quickly locate the specific location of the leak, resulting in low efficiency in problem handling and maintenance.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a heat exchanger water leakage alarm system, comprising a pipe 1 and a pipe 2, wherein the adjacent ends of the pipe 1 and the pipe 2 are fixedly connected with tube sheets, the two tube sheets are fixedly connected, and an alarm system is arranged on the pipe 1 and the pipe 2;

[0006] The alarm system includes a data acquisition module, the output end of the data acquisition module is electrically connected to a data processing module, the output end of the data processing module is electrically connected to a threshold analysis module, the output end of the threshold analysis module is electrically connected to a leakage detection module, the output end of the leakage detection module is electrically connected to a leakage alarm module, and the output end of the leakage alarm module is electrically connected to a leakage positioning module.

[0007] Preferably, the data acquisition module includes a temperature acquisition submodule, the output end of the temperature acquisition submodule is electrically connected to the humidity acquisition submodule, the output end of the humidity acquisition submodule is electrically connected to the pressure acquisition submodule, and the output end of the pressure acquisition submodule is electrically connected to the flow acquisition submodule.

[0008] Preferably, the data processing module comprises a data cleaning submodule, an output end of the data cleaning submodule is electrically connected to a data filtering submodule, and an output end of the data filtering submodule is electrically connected to a data formatting submodule.

[0009] Preferably, the threshold analysis module includes a threshold setting submodule, an output end of the threshold setting submodule is electrically connected to a dynamic adjustment submodule, and an output end of the dynamic adjustment submodule is electrically connected to a threshold storage submodule.

[0010] Preferably, the leakage detection module comprises a pattern comparison submodule, an output end of the pattern comparison submodule is electrically connected to a feature recognition submodule, and an output end of the feature recognition submodule is electrically connected to a multi-sensor fusion submodule.

[0011] Preferably, the leakage alarm module comprises an acoustic and visual alarm submodule, an output end of the acoustic and visual alarm submodule is electrically connected to a remote communication submodule, and an output end of the remote communication submodule is electrically connected to an alarm recording submodule.

[0012] Preferably, the leakage locating module comprises a sensor data locating submodule, an output end of the sensor data locating submodule is electrically connected to a signal strength analyzing submodule, and an output end of the signal strength analyzing submodule is electrically connected to a leakage position displaying submodule.

[0013] Working principle: Pipeline 1 and Pipeline 2 are connected through a tube sheet. The structure of the two tube sheets provides double protection to prevent leakage caused by corrosion, and isolates the liquid side and air side of Pipeline 1 from Pipeline 2 to prevent water from leaking into the motor or generator and avoiding major accidents. The alarm system can detect water leakage inside the heat exchanger in real time. The alarm system uses multi-sensor technology through the data acquisition module, including temperature sensors, pressure sensors and humidity sensors. It collects various operating data of the heat exchanger in real time through the industrial bus protocol. The sensor signal is converted into a digital signal through the analog-to-digital converter ADC to generate an initial data set; the data processing module is based on the data cleaning algorithm, outlier filtering and missing value filling to pre-process the initial data set, eliminate noise signals and invalid data, ensure the accuracy and completeness of the data, and use the smoothing filtering algorithm to reduce data fluctuations and generate cleaned data; the threshold analysis module is based on the adaptive threshold dynamic adjustment algorithm to analyze the cleaned data And set the leakage judgment threshold, compare the historical operating data with the real-time data, dynamically adjust the threshold range of parameters such as temperature, humidity and pressure, ensure the adaptability of the alarm threshold, and generate dynamic threshold parameters; the leakage detection module is based on the pattern recognition algorithm, and through the machine learning model: decision tree, compares and analyzes the cleaned data with the dynamic threshold parameters to identify whether there are leakage characteristics. At the same time, a multi-sensor fusion algorithm is introduced to enhance the accuracy of leakage detection and generate leakage detection results; the leakage alarm module is based on the leakage detection results, through the threshold judgment algorithm, when the leakage is detected to exceed the threshold range, the alarm system is triggered. The alarm system uses the sound and light alarm mechanism and the remote communication technology GPRS to send the alarm signal to the monitoring terminal to generate a leakage alarm signal; the leakage positioning module is based on the leakage alarm signal and sensor data, and uses the signal strength analysis method based on triangulation positioning to locate the specific location of the leakage. By fusing the change area of ​​the temperature, humidity and pressure sensors, the leakage point is accurately determined and a leakage location report is generated.

[0014] The present invention provides a heat exchanger water leakage alarm system, which has the following beneficial effects:

[0015] 1. The present invention significantly improves the accuracy of leak detection through the coordinated analysis of parameters such as temperature, humidity, pressure and flow, and avoids misjudgment caused by fluctuations in a single parameter. In the data processing process, a multi-step processing method of cleaning, filtering and formatting is adopted to enhance the stability and reliability of the collected data, and at the same time, the identification of abnormal signals is more efficient. In the threshold analysis link, the dynamic adjustment and storage mechanism enables the system to adapt to changes in different working conditions, realizes adaptive adjustment of threshold settings, and reduces the probability of false alarms due to fixed parameter settings.

[0016] 2. The present invention realizes rapid and accurate judgment of leakage through the combination of pattern comparison and feature recognition as well as multi-sensor fusion in the leakage detection link, while reducing the influence of external interference on the detection results.

[0017] 3. The present invention ensures that the alarm information can be quickly transmitted to the operator through the combination of sound, light and remote communication, avoiding delays in response time. By combining the positioning function of signal strength analysis and sensor data, the specific location can be quickly locked when a leak occurs, greatly improving maintenance efficiency and avoiding additional losses caused by inaccurate positioning. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A perspective view of the present invention;

[0019] Figure 2 It is a framework diagram of the alarm system of the present invention;

[0020] Figure 3 It is a system diagram of the data acquisition module of the present invention;

[0021] Figure 4 It is a system diagram of the data processing module of the present invention;

[0022] Figure 5 It is a system diagram of the threshold analysis module of the present invention;

[0023] Figure 6 is a system diagram of a leakage detection module of the present invention;

[0024] Figure 7 It is a system diagram of the leakage alarm module of the present invention;

[0025] Figure 8 This is a system diagram of the leakage positioning module of the present invention.

[0026] Among them, 1. Pipeline 1; 2. Pipeline 2; 3. Tube plate; 4. Alarm system; 41. Data acquisition module; 101. Temperature acquisition submodule; 102. Temperature acquisition submodule; 103. Pressure acquisition submodule; 104. Flow acquisition submodule; 42. Data processing module; 201. Data cleaning submodule; 202. Data filtering submodule; 203. Data formatting submodule; 43. Threshold analysis module; 301. Threshold setting submodule; 302. Dynamic adjustment submodule; 303. Threshold storage submodule; 44. Leakage detection module; 401. Pattern comparison submodule; 402. Feature recognition submodule; 403. Multi-sensor fusion submodule; 45. Leakage alarm module; 501. Sound and light alarm submodule; 502. Remote communication submodule; 503. Alarm recording submodule; 46. Leakage positioning module; 601. Sensor data positioning submodule; 602. Signal strength analysis submodule; 603. Leakage location display submodule. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] Example:

[0029] Please see attached Figure 1 - Attachment Figure 8 The embodiment of the present invention provides a water leakage alarm system for a heat exchanger, comprising a pipe 1 and a pipe 2, wherein adjacent ends of the pipe 1 and the pipe 2 are fixedly connected with a tube sheet 3, the two tube sheets 3 are fixedly connected, and an alarm system 4 is arranged on the pipe 1 and the pipe 2; the alarm system 4 comprises a data acquisition module 41, the output end of the data acquisition module 41 is electrically connected with a data processing module 42, the output end of the data processing module 42 is electrically connected with a threshold analysis module 43, the output end of the threshold analysis module 43 is electrically connected with a leakage detection module 44, the output end of the leakage detection module 44 is electrically connected with a leakage alarm module 45, and the output end of the leakage alarm module 45 is electrically connected with a leakage positioning module 46;

[0030] In this embodiment, pipe 1 and pipe 2 are connected through a tube sheet 3. The structure of the two tube sheets 3 provides double protection to prevent leakage caused by corrosion, and isolates the liquid side and air side of pipe 1 and pipe 2 2 to prevent water from leaking into the motor or generator, thereby avoiding major accidents. The alarm system 4 can detect water leakage inside the heat exchanger in real time. The alarm system 4 uses multi-sensor technology through a data acquisition module 41, including a temperature sensor, a pressure sensor, and a humidity sensor. Various operating data of the heat exchanger are collected in real time through an industrial bus protocol. The sensor signal is converted into a digital signal through an analog-to-digital converter ADC to generate an initial data set; the data processing module 42 pre-processes the initial data set based on a data cleaning algorithm, outlier filtering, and missing value filling to eliminate noise signals and invalid data to ensure the accuracy and integrity of the data. At the same time, a smoothing filtering algorithm is used to reduce data fluctuations and generate cleaned data; the threshold analysis module 43 analyzes the cleaning based on an adaptive threshold dynamic adjustment algorithm. The cleaned data is collected and the leakage judgment threshold is set. By comparing the historical working condition data with the real-time data, the threshold range of parameters such as temperature, humidity and pressure is dynamically adjusted to ensure the adaptability of the alarm threshold and generate dynamic threshold parameters; the leakage detection module 44 is based on the pattern recognition algorithm and the machine learning model: decision tree, which compares and analyzes the cleaned data with the dynamic threshold parameters to identify whether there are leakage characteristics. At the same time, a multi-sensor fusion algorithm is introduced to enhance the accuracy of leakage detection and generate leakage detection results; the leakage alarm module 45 is based on the leakage detection result and the threshold judgment algorithm. When the leakage exceeds the threshold range, the alarm system 4 is triggered. The alarm system 4 uses the sound and light alarm mechanism and the remote communication technology GPRS to send an alarm signal to the monitoring terminal to generate a leakage alarm signal; the leakage positioning module 46 is based on the leakage alarm signal and sensor data, and uses the signal strength analysis method based on triangulation positioning to locate the specific location of the leakage. By fusing the change area of ​​the temperature, humidity and pressure sensors, the leakage point is accurately determined and a leakage location report is generated.

[0031] The data acquisition module 41 includes a temperature acquisition submodule 101, the output end of the temperature acquisition submodule 101 is electrically connected to a humidity acquisition submodule 102, the output end of the humidity acquisition submodule 102 is electrically connected to a pressure acquisition submodule 103, and the output end of the pressure acquisition submodule 103 is electrically connected to a flow acquisition submodule 104;

[0032] Among them, the temperature acquisition submodule 102101 in the data acquisition module 41 adopts a temperature sensor acquisition algorithm to collect temperature data of the heat exchanger in real time, converts it into a digital signal through an analog-to-digital converter ADC, and generates a temperature data set; the humidity acquisition submodule collects humidity data around the heat exchanger based on a humidity sensor signal acquisition method, converts the sensor analog signal into a digital signal, and generates a humidity data set; the pressure acquisition submodule 103 adopts a pressure sensor acquisition method to monitor the internal and external pressure data of the heat exchanger in real time, transmits the data through a data bus protocol, and generates a pressure data set; the flow acquisition submodule 104 uses a flow sensor data acquisition algorithm to collect and transmit the flow parameters of the heat exchanger pipeline in real time to generate a flow data set.

[0033] The data processing module 42 includes a data cleaning submodule 201, the output end of the data cleaning submodule 201 is electrically connected to a data filtering submodule 202, and the output end of the data filtering submodule 202 is electrically connected to a data formatting submodule 203;

[0034] Among them, the data cleaning submodule 201 in the data processing module 42 removes abnormal data in the initial data set based on the outlier filtering algorithm, and adopts the missing value filling method to ensure data integrity, and generates a cleaned data set; the data filtering submodule 202, based on the median filtering algorithm, smoothes the cleaned data set, reduces noise interference, improves data quality, and generates a filtered data set; the data formatting submodule 203 standardizes the format of the filtered data set according to the time series and sensor category to facilitate subsequent analysis and generate a formatted data set.

[0035] The threshold analysis module 43 includes a threshold setting submodule 301, the output end of the threshold setting submodule 301 is electrically connected to a dynamic adjustment submodule 302, and the output end of the dynamic adjustment submodule 302 is electrically connected to a threshold storage submodule 303;

[0036] Among them, the threshold setting submodule 301 in the threshold analysis module 43, based on historical data comparison, uses statistical analysis methods to extract the key parameter range and preliminarily set the leakage judgment threshold, calls the formatted data set for data matching, and generates initial threshold parameters; the dynamic adjustment submodule 302 dynamically calibrates the initial threshold parameters based on the adaptive threshold adjustment algorithm, adjusts them in combination with the real-time status data of the formatted data set, and generates dynamic threshold parameters; the threshold storage submodule 303 stores the dynamic threshold parameters in the system database for leakage detection calls to generate the final threshold parameters.

[0037] The leakage detection module 44 includes a pattern comparison submodule 401, the output end of the pattern comparison submodule 401 is electrically connected to a feature recognition submodule 402, and the output end of the feature recognition submodule 402 is electrically connected to a multi-sensor fusion submodule 403;

[0038] Among them, the pattern comparison submodule in the leakage detection module 44 adopts a pattern matching algorithm to compare the formatted data set with the final threshold parameters one by one, identify the leakage characteristics, and generate leakage characteristic data; the feature recognition submodule 402 extracts features from the leakage characteristic data based on the random forest of the machine learning algorithm, identifies the possibility of leakage, and generates a preliminary leakage judgment; the multi-sensor fusion submodule 403 combines sensor data such as temperature, humidity, and pressure, and uses Ka lman filtering to further verify the accuracy of the preliminary leakage judgment to generate a leakage detection result.

[0039] The leakage alarm module 45 includes an audible and visual alarm submodule 501, the output end of the audible and visual alarm submodule 501 is electrically connected to a remote communication submodule 502, and the output end of the remote communication submodule 502 is electrically connected to an alarm recording submodule 503;

[0040] Among them, the sound and light alarm submodule 501 in the leakage alarm module 45 determines whether the leakage exceeds the threshold based on the leakage detection results, triggers the sound and light alarm device, and generates an sound and light alarm signal; the remote communication submodule 502 calls the sound and light alarm signal, sends the alarm signal to the monitoring platform through the communication protocol GPRS, and generates a remote alarm signal; the alarm record submodule 503 records the remote alarm signal and the leakage detection results, stores them in the alarm log database for subsequent analysis, and generates an alarm log record.

[0041] The leakage locating module 46 includes a sensor data locating submodule 601, the output end of the sensor data locating submodule 601 is electrically connected to a signal strength analyzing submodule 602, and the output end of the signal strength analyzing submodule 602 is electrically connected to a leakage position display submodule 603;

[0042] Among them, the sensor data positioning submodule in the leakage positioning module 46 analyzes the temperature, humidity and pressure sensor data based on the alarm log records, identifies the possible leakage area, and generates leakage area data; the signal strength analysis submodule 602 adopts a triangulation positioning algorithm to further determine the leakage point based on the leakage area data and the spatial position of the sensor, and generates leakage positioning data; the leakage position display submodule 603 calls the leakage positioning data, displays the leakage position and related parameters on the monitoring terminal through graphical display technology, and generates a leakage position report.

[0043] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A heat exchanger water leakage alarm system, comprising a pipe 1 (1) and a pipe 2 (2), characterized in that: The adjacent ends of the pipeline 1 (1) and the pipeline 2 (2) are fixedly connected with a tube sheet (3), the two tube sheets (3) are fixedly connected, and the pipeline 1 (1) and the pipeline 2 (2) are provided with an alarm system (4); The alarm system (4) comprises a data acquisition module (41), the output end of the data acquisition module (41) is electrically connected to a data processing module (42), the output end of the data processing module (42) is electrically connected to a threshold analysis module (43), the output end of the threshold analysis module (43) is electrically connected to a leakage detection module (44), the output end of the leakage detection module (44) is electrically connected to a leakage alarm module (45), and the output end of the leakage alarm module (45) is electrically connected to a leakage positioning module (46).

2. The heat exchanger water leakage alarm system according to claim 1, characterized in that: The data acquisition module (41) comprises a temperature acquisition submodule (101), the output end of the temperature acquisition submodule (101) is electrically connected to a humidity acquisition submodule (102), the output end of the humidity acquisition submodule (102) is electrically connected to a pressure acquisition submodule (103), and the output end of the pressure acquisition submodule (103) is electrically connected to a flow acquisition submodule (104).

3. The heat exchanger water leakage alarm system according to claim 1, characterized in that: The data processing module (42) comprises a data cleaning submodule (201), the output end of the data cleaning submodule (201) is electrically connected to a data filtering submodule (202), and the output end of the data filtering submodule (202) is electrically connected to a data formatting submodule (203).

4. The heat exchanger water leakage alarm system according to claim 1, characterized in that: The threshold analysis module (43) comprises a threshold setting submodule (301), the output end of the threshold setting submodule (301) is electrically connected to a dynamic adjustment submodule (302), and the output end of the dynamic adjustment submodule (302) is electrically connected to a threshold storage submodule (303).

5. The heat exchanger water leakage alarm system according to claim 1, characterized in that: The leakage detection module (44) comprises a pattern comparison submodule (401), the output end of the pattern comparison submodule (401) is electrically connected to a feature recognition submodule (402), and the output end of the feature recognition submodule (402) is electrically connected to a multi-sensor fusion submodule (403).

6. The heat exchanger water leakage alarm system according to claim 1, characterized in that: The leakage alarm module (45) comprises an audible and visual alarm submodule (501), the output end of the audible and visual alarm submodule (501) being electrically connected to a remote communication submodule (502), and the output end of the remote communication submodule (502) being electrically connected to an alarm recording submodule (503).

7. The heat exchanger water leakage alarm system according to claim 1, characterized in that: The leakage locating module (46) comprises a sensor data locating submodule (601), the output end of the sensor data locating submodule (601) is electrically connected to a signal strength analysis submodule (602), and the output end of the signal strength analysis submodule (602) is electrically connected to a leakage position display submodule (603).

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