Monitoring probe and method for manufacturing monitoring probe

Abstract

The present invention provides a monitoring probe capable of detecting both a loss amount and a corrosion state, and a method for manufacturing the monitoring probe. A monitoring probe according to the present disclosure is provided with: a cylindrical outer tube part having a hollow inside; an ultrasonic sensor which is provided on the inner wall side of the outer cylinder part and measures the wall thickness of the outer cylinder part by means of reflected waves of ultrasonic waves from the outer wall of the outer cylinder part; a dual-electrode sensor which is provided in the outer cylinder part and measures a current value between the two electrodes generated by the melting of the adhering ash; and a thermocouple which is provided in the outer cylinder part and measures the temperature of the outer cylinder part.

Description

Technical Field

[0001] The present disclosure relates to a monitoring detector and a method for manufacturing the monitoring detector. Background Art

[0002] In furnaces such as waste incinerator boilers, sodium recovery boilers, and coal-fired boilers, and in flue gas ducts, fuels such as coal or waste contain chlorine, heavy metals, sulfur, and vanadium, etc., and corrosion of metal materials such as superheater tubes of boilers sometimes occurs. In particular, in waste incinerator boilers, corrosion of the boiler superheater tubes due to the influence of low-melting corrosion components such as high chlorine and heavy metals is a concern. However, in waste incinerator boilers, since the fuel properties vary greatly, it is difficult to predict in advance the life of the boiler superheater tubes.

[0003] For example, in Patent Document 1 described below, a corrosion monitoring sensor is disclosed, which is a corrosion monitoring sensor for a waste incinerator boiler or the like. The corrosion monitoring sensor has an electrode portion substrate as an insulator on a part of the side surface of a metal detector, and a specimen electrode, a counter electrode, and a reference electrode made of a metal to be evaluated are provided on the electrode portion substrate.

[0004] Prior Art Documents

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2005-91281 Summary of the Invention

[0006] Problems to be Solved by the Invention

[0007] However, the corrosion monitoring sensor described in Patent Document 1 has a problem that the electrodes need to be replaced regularly. In view of the above problems, an object of the present disclosure is to provide a monitoring detector and a method for manufacturing the monitoring detector that can detect both the amount of wear and the corrosion state.

[0008] Means for Solving the Problems

[0009] To solve the above problems and achieve the object, the monitoring detector of the present disclosure includes: a cylindrical outer cylinder portion having a hollow interior; an ultrasonic sensor provided on the inner wall side of the outer cylinder portion for measuring the wall thickness of the outer cylinder portion by a reflected wave of ultrasonic waves from the outer wall of the outer cylinder portion; a double electrode sensor provided on the outer cylinder portion for measuring the current value between two electrodes generated by melting of adhered ash; and a thermocouple provided on the outer cylinder portion for measuring the temperature of the outer cylinder portion.

[0010] In order to solve the above problems and achieve the object, the manufacturing method of the monitoring detector of the present disclosure includes the following steps: a step of preparing a material constituting the outer cylinder portion of the monitoring detector; a step of forming a piezoelectric element on the above material; a step of assembling, pasting, and wiring an ultrasonic sensor; a step of welding the outer cylinder portion of the monitoring detector; and a step of inserting a core into the inside of the above outer cylinder portion.

[0011] According to the present disclosure, it is possible to provide a monitoring detector capable of detecting both the amount of damage and the corrosion environment, and a manufacturing method of the monitoring detector. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram showing a structural example of the monitoring detector of the present disclosure.

[0013] Figure 2 It is a schematic diagram showing a first mode of the ultrasonic sensor of the present disclosure.

[0014] Figure 3 It is a schematic diagram showing a second mode of the ultrasonic sensor of the present disclosure.

[0015] Figure 4 It is a schematic diagram showing a third mode of the ultrasonic sensor of the present disclosure.

[0016] Figure 5 It is a graph showing the time-series change of the measured value of the ultrasonic sensor of the present disclosure.

[0017] Figure 6 It is a schematic diagram showing a structural example of the double electrode sensor of the present disclosure.

[0018] Figure 7 It is a schematic diagram showing a shape example of the substrate portion and the double electrode portion of the double electrode sensor of the present disclosure.

[0019] Figure 8 It is a graph showing the time-series change of the measured value of the double electrode sensor of the present disclosure.

[0020] Figure 9 It is a flowchart showing the process of the first mode of the manufacturing method of the monitoring detector of the present disclosure.

[0021] Figure 10 It is a process diagram showing the process of the first mode of the manufacturing method of the monitoring detector of the present disclosure.

[0022] Figure 11 It is a flowchart showing the process of the second mode of the manufacturing method of the monitoring detector of the present disclosure.

[0023] Figure 12 It is a process diagram showing the process of the second mode of the manufacturing method of the monitoring detector of the present disclosure. Detailed implementation manners

[0024] Hereinafter, embodiments of the present disclosure will be described in detail based on the accompanying drawings. In addition, the present disclosure is not limited to the embodiments described below.

[0025] (Structure of the monitoring detector)

[0026] The monitoring detector 10 is provided in the furnace or flue of a waste incineration boiler, a sodium recovery boiler, a coal-fired boiler, etc., and is a detector that simulates the corrosion of metal materials such as superheater tubes under high-temperature environments and monitors the corrosion. Use Figure 1 to illustrate the structure of the monitoring detector 10. Figure 1 is a schematic diagram showing a structural example of the monitoring detector of the present disclosure. As Figure 1 shown, the monitoring detector 10 includes: an outer cylinder portion 11, an ultrasonic sensor 12, a double-electrode sensor 13, a thermocouple 14, and a core 15.

[0027] The outer cylinder portion 11 is a cylindrical outer cylinder with a hollow interior. The outer cylinder portion 11 simulates superheater tubes of a boiler, etc. The outer cylinder portion 11 can be in the shape of a square tube or a round tube. In addition, an ultrasonic sensor 12 and the like described later are provided on the outer cylinder portion 11. Therefore, from the viewpoints of sensor installation, responsiveness, and manufacturability, the outer cylinder portion 11 is preferably in the shape of a square tube that can form a flat side surface. The material of the outer cylinder portion 11 can be made of the same material as the material of the portion that is the evaluation object of the corrosion state of the boiler. For example, the material of the outer cylinder portion 11 can be carbon steel, low-alloy steel, stainless steel, Ni-based alloy, etc. used for superheater tubes of a boiler. In addition, these various materials can also be combined to manufacture the outer cylinder portion 11. For example, it can also be that the front end portion of the outer cylinder portion 11 is formed of Ni-based alloy, the central portion is formed of carbon steel, and the support portion is formed of stainless steel. Thereby, it is possible to simulate the wear amount and corrosion state of multiple structures of the boiler and monitor using one detector.

[0028] The ultrasonic sensor 12 is provided on the inner wall side of the outer cylinder portion 11, and measures the wall thickness of the outer wall of the outer cylinder portion 11 by the reflected wave of ultrasonic waves from the outer wall of the outer cylinder portion 11. As Figure 1 shown, the ultrasonic sensor 12 is provided at multiple positions inside the outer cylinder portion 11. For example, as Figure 1As shown, it can be provided at the front end portion, the central portion, and the support portion of the outer cylinder portion 11 on the upstream side and the downstream side in the traveling direction of the combustion gas G inside the outer cylinder portion 11, respectively. Since the combustion gas temperature inside the boiler and the metal temperature in the length direction of the detector vary depending on the location, the progress form of corrosion also varies depending on the location. By providing the ultrasonic sensor 12 at multiple locations on the outer cylinder portion 11, it is possible to measure the wall thickness of the outer cylinder portion 11 at multiple locations with different temperature conditions. In a narrow space such as the monitoring detector 10, a normal ultrasonic sensor is too large. In addition, when installed on the outer wall, it is sometimes difficult to install from the perspective of durability against exposure to a harsh corrosion environment. Moreover, a normal ultrasonic sensor has problems with heat resistance. On the other hand, if it is the ultrasonic sensor 12 of the present application, it is possible to easily measure multiple locations of the monitoring detector 10 on the basis of being thin, miniaturized, and ensuring heat resistance.

[0029] The ultrasonic sensor 12 transmits and receives ultrasonic waves through the piezoelectric element 121. That is, the ultrasonic waves transmitted by the piezoelectric element 121 are transmitted inside the outer cylinder portion 11, and the piezoelectric element 121 receives the reflected wave reflected from the outer wall of the outer cylinder portion 11. The piezoelectric element 121 is formed of a material that exhibits the property of expanding and contracting when a voltage is applied. Therefore, by applying a high-frequency voltage (frequency of 20 kHz or more) to the piezoelectric element 121, the piezoelectric element 121 expands and contracts according to the voltage. That is, it can be said that the piezoelectric element 121 performs high-frequency vibration, thereby generating ultrasonic waves. The wall thickness of the outer cylinder portion 11 is proportional to the time interval of the reflected wave. Therefore, it is possible to obtain the wall thickness of the outer cylinder portion 11 by measuring the time interval of the reflected wave. The ultrasonic sensor 12 measures the wall thickness of the outer cylinder portion 11 using such a principle. In addition, the specific structure of the ultrasonic sensor 12 will be described later.

[0030] The double-electrode sensor 13 is provided on the outer wall side of the outer cylinder portion 11 and measures the current value between the two electrodes generated due to the melting of the attached ash. As Figure 1 shown, the double-electrode sensor 13 is provided to block the hole formed by digging through the outer wall on the upstream side in the traveling direction of the combustion gas G of the outer cylinder portion 11. As Figure 1As shown, the double electrode sensor 13 can be provided at the front end portion, the central portion, and the support portion on the outer wall on the upstream side in the traveling direction of the combustion gas G flow in the outer cylinder portion 11. Similar to the combustion gas temperature, the ash adhesion mode also varies depending on the location. Therefore, by providing the double electrode sensor 13 at multiple locations on the outer cylinder portion 11, it is possible to detect the melting of the ash adhered to multiple locations with different combustion gas temperatures and adhesion modes. In addition, the structure of the double electrode sensor 13 is simple and has excellent durability, and it does not induce the adhesion of ash like multiple electrodes. In addition, by increasing the contact area with the electrode, the double electrode sensor 13 can detect an increase in the adhesion thickness of the ash as a decrease in resistance. In this way, even a simple structure can obtain a large amount of information related to the phenomenon.

[0031] In addition, most of the ash adhered to the superheater tubes of the boiler adheres to the surface in a solid state. However, when the surface temperature of the superheater tubes of the boiler rises, the adhered ash is heated above the melting temperature, and thus the adhered ash melts and becomes a conductive liquid. Therefore, in a state where two electrodes not electrically connected to each other are arranged, when ash adheres between them and is heated above the melting temperature, the ash becomes a conductive liquid, and current flows between the two electrodes via the conductive liquid. The double electrode sensor 13 is a sensor that utilizes such a principle to detect the melting of the adhered ash. In addition, the specific structure of the double electrode sensor 13 will be described later.

[0032] The thermocouple 14 is provided inside and outside the outer cylinder portion 11 for temperature measurement and metal temperature control of the monitoring detector 10 based on the cooling air C, and measures the temperature of the outer cylinder portion 11. As Figure 1 shown, the thermocouple 14 can be provided, for example, at the front end portion, the central portion, and the support portion on the outer side of the outer wall on the upstream side in the traveling direction of the combustion gas G flow in the outer cylinder portion 11. In addition, the thermocouple 14 can be provided at the central portion on the inner side of the outer wall on the upstream side in the traveling direction of the combustion gas G flow in the outer cylinder portion 11.

[0033] The combustion gas temperature of the incinerator of the waste incineration boiler is heated to a temperature within a temperature range of, for example, about 400°C to 700°C. The progress of high-temperature corrosion of materials such as the superheater tubes of the boiler is affected by temperature conditions. Therefore, the thermocouple 14 measures the temperature of the outer cylinder portion 11 of the monitoring detector 10 that simulates the superheater tubes of the boiler. In addition, the temperature varies according to the position of the monitoring detector 10, and the progress form of corrosion varies according to this temperature. Therefore, by providing the thermocouple 14 at multiple parts of the monitoring detector 10, the influence of temperature conditions on the progress of corrosion can be considered. Moreover, by providing the thermocouple 14 inside the outer wall of the outer cylinder portion 11, the cooling of the cooling air C can be monitored. Therefore, feedback control of the amount of cooling air supplied to the inside of the outer cylinder portion 11 can be performed.

[0034] The core 15 fills the voids other than the portions where the ultrasonic sensor 12 and the double-electrode sensor 13 are provided inside the outer cylinder portion 11. The core 15 can be formed, for example, in a square column shape or a cylindrical shape. In addition, the material of the core 15 can be the same material as that used for the outer cylinder portion 11. For example, as Figure 1 shown, the core 15 can be formed in a cylindrical shape and is arranged inside the outer cylinder portion 11 at a position coaxial with the axis of the outer cylinder portion 11. By providing the core 15 inside the outer cylinder portion 11, the voids inside the outer cylinder portion 11 can be filled. Therefore, the supply amount of the cooling air C supplied to the outer cylinder portion 11 can be reduced. In addition, by providing the core 15, the cross-sectional area of the flow path of the cooling air C inside the outer cylinder portion 11 becomes smaller, so the flow velocity of the cooling air C can be increased. As a result, the cooling efficiency of the cooling air C can be improved.

[0035] The cooling air supply system supplies the cooling air C to the inside of the outer cylinder portion 11. The cooling air supply system can be realized, for example, by a compressor, a receiver, a manifold, a flow rate adjustment valve, and a pressure adjustment valve. In this case, the compressed air compressed by the compressor is supplied to the receiver, and the receiver removes the pressure pulsation generated by the compressor. The compressed air supplied from the receiver is branched by the manifold to multiple supply destinations. The compressed air branched by the manifold adjusts the pressure through the pressure adjustment valve. The compressed air whose pressure has been adjusted by the pressure adjustment valve adjusts the flow rate through the flow rate adjustment valve and is supplied to the inside of the outer cylinder portion 11.

[0036] The cooling air C supplied to the inside of the outer cylinder portion 11 cools the outer wall of the outer cylinder portion 11 and the ultrasonic sensor 12 provided on the outer wall while flowing on the upper side thereof, and flows through the inside of the outer cylinder portion 11 and out into the furnace. As Figure 1 shown, the monitoring detector 10 is arranged in the flow path of the high-temperature combustion gas G. Therefore, as shown in the temperature distribution of the detector tube cross-section (the thick shaded line indicates a high temperature, and the light shaded line indicates a low temperature), the front end portion is particularly in a high-temperature state. For example,Figure 1 The temperature of TA shown is approximately 390 °C, the temperature of TB is approximately 470 °C, and the temperature of TC is approximately 530 °C. Therefore, by supplying cooling air C to the inside of the outer cylinder portion 11 using the cooling air supply system, the ultrasonic sensor 12 and the double electrode sensor 13 arranged in a high-temperature environment can be cooled. Therefore, the lifespan during which they can operate stably can be extended.

[0037] In addition, although not the structure of the monitoring detector 10, a temperature detector TP such as a thermocouple can also be provided on the upstream side of the gas flow of the combustion gas G of the monitoring detector 10 to measure the combustion gas temperature. Since the progress form of high-temperature corrosion is affected by temperature conditions, the influence of the combustion gas temperature on high-temperature corrosion can be studied.

[0038] According to such a structure, the monitoring detector 10 can detect both the wear amount and the corrosion state. In addition, by changing the material of the outer cylinder portion 11 of the monitoring detector 10 according to the part, multiple components of the boiler can be simulated. Therefore, the wear amounts and corrosion states of multiple components of the boiler can be estimated by one monitoring detector 10.

[0039] (Structure of ultrasonic sensor)

[0040] (First mode)

[0041] Next, Figure 2 is used to explain the first mode of the ultrasonic sensor 12. Figure 2 is a schematic diagram showing the first mode of the ultrasonic sensor of the present disclosure. As Figure 2 shown, the ultrasonic sensor 12 of the first mode includes: a piezoelectric element 121, an upper electrode 122, a lead-out wire 123, a saddle portion 124, and a signal wire 125.

[0042] The piezoelectric element 121 is formed by directly coating a solution containing powder of piezoelectric ceramics on the outer cylinder portion 11 and performing heat treatment. As the material used for the piezoelectric element 121, for example, lead zirconate titanate (PZT: Pb(Zr,Ti)O 3 ), lithium niobate (LNB: LiNbO 3 ) etc. can be used. The film thickness of the piezoelectric element 121 can be, for example, 80 μm to 100 μm.

[0043] The upper electrode 122 is provided on the upper part of the piezoelectric element 121 and is an electrode electrically connected to the piezoelectric element 121. The upper electrode 122 can be realized, for example, by forming a silver paste film on the upper part of the piezoelectric element 121.

[0044] The lead-out wire 123 is disposed above the upper electrode 122 and electrically connects the upper electrode 122 to the signal wire 125. The lead-out wire 123 can be, for example, a silver (Ag) wire. By using a silver wire for the lead-out wire 123, even when the ultrasonic sensor 12 is exposed to a usage environment with a high temperature of 300 °C or higher, electrical conduction can be achieved without melting.

[0045] The saddle portion 124 is a support member that fixes the signal wire 125 to the outer cylinder portion 11. The saddle portion 124 can fix and support the signal wire 125 to the outer wall through, for example, a stainless steel foil, an iron saddle, a stainless steel saddle, a single saddle, a leaf spring, etc.

[0046] The signal wire 125 is electrically connected to the upper electrode 122 via the lead-out wire 123 and is connected to an external device. The signal wire 125 is a coaxial cable and can be realized, for example, by using an inorganic insulation (MI: Mineral Insulated) cable. The MI cable is a cable used in a high-temperature environment or a harsh environment. The MI cable has a wire portion for transmitting an electrical signal and a sheath portion covering the wire portion, and an insulator such as magnesium oxide is filled between them. Magnesium oxide is a non-reactive insulator, so it can prevent the current flowing through the wire portion from being affected by the outside. In addition, the sheath portion that covers and protects the wire portion of the MI cable is formed of a Ni-based alloy, so long-term measurement can be performed even in a high-temperature environment.

[0047] According to this structure, it is possible to maintain the state in which the ultrasonic sensor 12 is in contact with the outer cylinder portion 11 of the monitoring detector 10 without using an adhesive whose adhesive force is worried about decreasing in a high-temperature environment. Therefore, long-term stable use of the ultrasonic sensor 12 in a high-temperature environment can be achieved.

[0048] (Structure of ultrasonic sensor)

[0049] (Second mode)

[0050] Next, use Figure 3 to illustrate the second mode of the ultrasonic sensor 12. Figure 3 is a schematic diagram showing the second mode of the ultrasonic sensor of the present disclosure. As Figure 3 shown, the ultrasonic sensor 12 of the second mode includes: a sensor unit 12B, a pressing portion 126, and a protection portion 127.

[0051] The sensor unit 12B has the same structure as the ultrasonic sensor 12A of the first mode except that an adhesive is added. That is, the sensor unit 21B is composed of a piezoelectric element 121, an upper electrode 122, a lead-out wire 123, a saddle portion 124, and a signal wire 125.

[0052] The pressing portion 126 presses the piezoelectric element 121 against the outer cylinder portion 11. The pressing portion 126 can be realized by a jig, for example. For example, a structure is adopted in which the fixing portion of the jig is fixedly supported on the outer cylinder portion 11 in advance, and the piezoelectric element 121 is pressed by rotating the threaded portion of the jig, whereby the pressing portion P can be realized. Thereby, a pressing force can be applied to the piezoelectric element 121, so that the contact state between the ultrasonic sensor 12 and the outer cylinder portion 11 can be maintained even in a high-temperature environment where the adhesive force of the adhesive is concerned to decrease. Therefore, the ultrasonic sensor 12 can be used stably.

[0053] The protection portion 127 covers the sensor unit 12B and protects the sensor unit 12B from breakage or damage that may occur to the sensor unit 12B due to the pressing force of the pressing portion 126. The protection portion 127 can be formed of a stainless-steel foil, for example. The protection portion 127 covers the entire surface of the sensor unit 12B and protects the sensor unit 12B from the pressing force of the threaded portion of the jig.

[0054] According to this structure, the contact state between the ultrasonic sensor 12 and the outer cylinder portion 11 can be maintained even in a high-temperature environment where the adhesive force of the adhesive is concerned to decrease. Therefore, the ultrasonic sensor 12 can be used stably for a long time.

[0055] (Structure of ultrasonic sensor)

[0056] (Third mode)

[0057] Next, use Figure 4 to illustrate the third mode of the ultrasonic sensor 12. Figure 4 is a schematic diagram showing the third mode of the ultrasonic sensor of the present disclosure. As Figure 4 shown, the ultrasonic sensor 12 of the third mode includes: a sensor unit 12B, a pressing portion 126, a protection portion 127, and a fastening portion 128. As Figure 4 shown, the ultrasonic sensor 12 of the third mode has fastening portions 128 at both ends of the pressing portion 126, and a pressing load is applied to the sensor unit 12B via the pressing portion 126 by the fastening portions 128.

[0058] The sensor unit 12B and the protection portion 127 in the structure of the third mode of the ultrasonic sensor 12 are the same as those in the second mode. Therefore, regarding the third mode of the ultrasonic sensor 12, the pressing portion 126 and the fastening portion 128, which are structures different from the second mode, will be described.

[0059] As Figure 4As shown, the pressing portion 126 of the third mode of the ultrasonic sensor 12 may be a flat metal plate having holes for the fastening portion 128 to pass through at both ends. The pressing portion 126 of the third mode contacts the sensor unit 12B through the plane of the flat metal plate, and presses the sensor unit 12B against the outer cylinder portion 11.

[0060] The fastening portion 128 is provided at the end of the pressing portion 126 of the third mode of the ultrasonic sensor 12, and is inserted into the bolt hole provided in the outer cylinder portion 11 to press the pressing portion 126 against the sensor unit 12B. The fastening portion 128 can be realized by, for example, bolts and nuts.

[0061] According to the third mode of the ultrasonic sensor 12, the pressing load can be easily adjusted by adjusting the fastening force of the fastening portion 128, and the manufacturing is easy.

[0062] Use Figure 5 to illustrate the time-series change of the measurement value of the ultrasonic sensor 12 having such a structure. Figure 5 It is a graph showing the time-series change of the measurement value of the ultrasonic sensor of the present disclosure. Figure 5 The horizontal axis of uses the unit of month to represent the operation time of the waste incinerator boiler. Figure 5 The vertical axis of represents the time-series change of the detector wall thickness measured by the ultrasonic sensor 12. As Figure 5 shown, it can be seen that there is a tendency for the detector wall thickness to decrease as the operation time elapses.

[0063] (Structure of double-electrode sensor)

[0064] Next, use Figure 6 to illustrate the structure of the double-electrode sensor 13. Figure 6 It is a schematic diagram showing a structural example of the double-electrode sensor of the present disclosure. As Figure 6 shown, the double-electrode sensor 13 according to the present disclosure includes: a fastening portion 131, a substrate portion 132, and a double-electrode portion 133. In addition, as Figure 6 shown, a thermocouple 14 may be provided on the substrate portion 132 of the double-electrode sensor 13. In addition, as Figure 6 shown, a sensor wire is connected to the double-electrode portion 133 and is connected to the processing device 20 via the sensor wire. A hole communicating with the cooling air flow path is provided in the detector recess of the outer cylinder portion 11 provided in Figure 6 , and the sensor wire is laid inside the outer cylinder portion 11 through this hole and is connected to the processing device 20. Thereby, the corrosion and deterioration of the sensor wire can be suppressed by laying the sensor wire inside the outer cylinder portion 11.

[0065] The fastening portion 131 is a fastening member that fixedly supports the substrate portion 132 to the outer cylinder portion 11. The fastening portion 131 can be realized, for example, by a combination of a ceramic bolt made of alumina (Al 2 O 3 ) having a heat-resistant temperature and two nuts (double nuts). In addition, by performing fastening based on the double nuts, loosening prevention of the nuts can be achieved.

[0066] The substrate portion 132 is a substrate having electrical insulation properties and formed with a double electrode portion 133. The substrate portion 132 can be formed of oxide-based ceramics such as alumina (Al 2 O 3 ), yttria-stabilized zirconia (YSZ), mullite, ceramics with excellent thermal conductivity such as aluminum nitride (AlN), silicon nitride (SiN), etc. By using these ceramic materials, electrical insulation properties can be maintained even in a high-temperature environment, and it can function as the substrate of the double electrode sensor 13 without melting. In addition, the corrosion resistance of the ceramic material is extremely high, so it has resistance to the severe corrosion environment exposed on the outer wall side of the outer cylinder portion 11 of the monitoring detector 10.

[0067] Here, Figure 7 is used to illustrate an example of the specific shape of the substrate portion 132. Figure 7 is a schematic diagram showing an example of the shape of the substrate portion and the double electrode portion of the double electrode sensor of the present invention. As Figure 7 shown, the substrate portion 132 can be formed in a quadrilateral plate shape. The thickness, lateral dimension, and longitudinal dimension of the substrate portion 132 can be arbitrarily set according to the dimensions of the outer cylinder portion 11, etc.

[0068] The double electrode portion 133 is formed by two electrodes that are not electrically connected to each other. The double electrode portion 133 can be formed, for example, by a central electrode 133A having a circular ring shape and a second electrode 133B having a circular ring shape with a diameter larger than that of the central electrode 133A. The double electrode portion 133 can be formed of platinum (Pt), for example. Here, Figure 7 is used to illustrate an example of the shape of the double electrode portion 133. As Figure 7 shown, the double electrode portion 133 can form a second electrode 133B having a circular ring shape with a diameter larger than that of the central electrode 133A around the central electrode 133A having a circular ring shape. Thus, when ash adheres between the electrodes and is heated to a temperature above the melting temperature and becomes a conductive liquid, current flows between the electrodes. Therefore, the melting of the adhered ash can be detected.

[0069] According to the double electrode sensor 13 having such a structure, the melting of the adhered ash generated in a high-temperature environment can be stably detected.

[0070] Use Figure 8The time series change of the measurement value of the two-electrode sensor 13 having such a structure will be described. Figure 8 It is a diagram showing the time series change of the measurement value of the two-electrode sensor of the present invention. Figure 8 The horizontal axis uses months to represent the operating time of the waste incinerator boiler. Figure 8 The vertical axis of represents the inter-electrode current as an example of a measurement value measured using the two-electrode sensor 13. Figure 8 As shown, when a current is measured between the two electrodes, for example, the combustion gas temperature rises due to a change in the properties of the garbage, and the temperature of the detector surface rises accordingly, and the attached ash is heated, and it is estimated that the attached ash is melted. In this way, by using the measurement value of the two-electrode sensor 13, the property change of the garbage put into the garbage incinerator and the melting state of the attached ash can be estimated.

[0071] (Manufacturing method of monitoring detector)

[0072] (First method)

[0073] Next, use Figure 9 and Figure 10 A first embodiment of a method for manufacturing the monitoring probe 10 of the present disclosure will be described. Figure 9 This is a flowchart showing the flow of a first embodiment of the method for manufacturing a monitoring probe according to the present disclosure. Figure 10 is a process diagram showing the process of the first embodiment of the manufacturing method of the monitoring detector disclosed in the present invention. Figure 9 , Figure 10 In the first embodiment of the manufacturing method of the monitoring probe 10 shown in FIG. 1 , the first embodiment of the ultrasonic sensor 12 is used. Figure 9 The flowchart shown, Figure 10 The process diagram shown in the figure explains a first embodiment of the method for manufacturing the monitoring probe 10.

[0074] First, prepare the materials for the detector (step S1). For example, prepare the angle bar 202 made of the specified material as the detector material and subjected to beveling. Next, form a piezoelectric element on the detector material and fire it (step S2). For example, use the processing equipment 203 to form a film of lead zirconate titanate and lithium niobate on the inner surface of the detector material and fire it. Thus, the piezoelectric element 204 is formed on the surface of the angle bar 202. Next, perform sensor assembly, pasting, and wiring (step S3). For example, perform operations such as installing the upper electrode 206, installing and wiring the signal line on the surface of the piezoelectric element 204. Next, manufacture the detector (step S4). For example, weld while aligning with another angle bar 210 at the beveled position of the angle bar 202. Thus, a detector is formed in which the sensor element 212 is disposed inside the cylindrical space assembled by the angle bar 202 and the angle bar 210. Next, assemble the detector (step S5). For example, perform operations such as installing the flange of the extraction groove with the sensor wire and inserting the core 220. Next, connect to the measuring instruments and equipment (step S6). For example, connect the signal line 125 to the processing device 20.

[0075] Thus, without using an adhesive whose adhesive force decreases in a high-temperature environment, the monitoring detector 10 equipped with the ultrasonic sensor 12 can be manufactured. Therefore, a monitoring detector 10 that can operate stably even in a high-temperature state can be provided.

[0076] (Second mode)

[0077] Next, use Figure 11 and Figure 12 to describe the second mode of the manufacturing method of the monitoring detector 10 of the present disclosure. Figure 11 is a flowchart showing the process of the second mode of the manufacturing method of the monitoring detector of the present disclosure. Figure 12 is a process diagram showing the processes of the first mode of the manufacturing method of the monitoring detector of the present disclosure. In addition, in Figure 11 , Figure 12 the manufacturing method of the monitoring detector 10 shown, the second mode using the ultrasonic sensor 12. According to the flowchart shown in Figure 11 and the process diagram shown in Figure 12 , the second mode of the manufacturing method of the monitoring detector 10 will be described. In addition, Figure 11 , Figure 12 the steps S1 and steps S4 to S6 in each step of the second mode of the manufacturing method of the monitoring detector 10 shown are the same as steps S1 and steps S4 to S6 of the first mode, so the description thereof is omitted.

[0078] In the manufacturing method of the second mode, the second mode of the ultrasonic sensor 12 is fabricated in steps S2 and S25. Specifically, a piezoelectric element is formed on a substrate and fired (step S2). For example, a piezoelectric element 312 is formed on a thin stainless-steel plate 310 and fired. Next, an ultrasonic sensor 320 is fabricated (step S25). For example, an upper electrode 314 is provided on the piezoelectric element 312, and signal lines are installed. Then, sensor assembly, adhesion, and wiring are performed (step S3). For example, the ultrasonic sensor 320 is installed on the inner surface of the angle member 202 by an adhesive 316, a pressing load is applied to the ultrasonic sensor 320 by a pressing portion 126, signal lines 125 are wired, and a thermocouple 14 etc. are installed. Additionally, in Figure 12 the pressing portion 126 is schematically indicated by an arrow.

[0079] Thereby, a monitoring detector 10 can be manufactured that can maintain the contact state between the ultrasonic sensor 12 and the outer cylinder portion 11 even in a high-temperature environment. Therefore, a monitoring detector 10 that can operate stably even in a high-temperature state can be provided.

[0080] (Structure and effects)

[0081] The present invention discloses the following inventions. Additionally, it is not limited to the following.

[0082] (1) A monitoring detector, comprising: a cylindrical outer cylinder portion 11 with an internal cavity formed; an ultrasonic sensor 12 provided on the inner wall side of the outer cylinder portion 11 that measures the wall thickness of the outer cylinder portion 11 through the reflected wave of ultrasonic waves from the outer wall of the outer cylinder portion 11; a double-electrode sensor 13 provided on the outer cylinder portion 11 that measures the current value between two electrodes due to the melting of adhered ash; and a thermocouple (14) provided on the outer cylinder portion 11 that measures the temperature of the outer cylinder portion 11.

[0083] According to this structure, a monitoring detector 10 that can detect both the amount of wear and the corrosion state can be provided.

[0084] (2) The monitoring detector according to (1), wherein the monitoring detector further comprises a cooling air supply system that supplies cooling air C to the inside of the outer cylinder portion 11.

[0085] According to this structure, the outer cylinder portion 11 of the monitoring detector 10 exposed to high-temperature combustion gas can be cooled. Therefore, a monitoring detector 10 that can stably detect both the amount of wear and the corrosion state even in a high-temperature environment can be provided.

[0086] (3) The monitoring detector according to (1) or (2), wherein the monitoring detector further comprises a core 15 that fills the cavity inside the outer cylinder portion 11 except for the portions where the ultrasonic sensor 12 and the double-electrode sensor 13 are installed.

[0087] According to this structure, the supply amount of the cooling air supplied to the outer cylinder part 11 can be reduced. In addition, by providing the core 15, the cross-sectional area of the flow path of the cooling air inside the outer cylinder part 11 becomes smaller, so that the flow velocity of the cooling air can be increased. As a result, the cooling efficiency of the cooling air can be improved.

[0088] (4) The monitoring detector according to (1) or (2), wherein the ultrasonic sensor 12 includes a piezoelectric element 121 formed directly on the inner wall of the outer cylinder part 11.

[0089] According to this structure, without using an adhesive that is worried about a decrease in adhesive force in a high-temperature environment, the state in which the ultrasonic sensor 12 is in contact with the outer cylinder part 11 of the monitoring detector 10 can be maintained. Therefore, long-term stable use of the ultrasonic sensor 12 in a high-temperature environment can be achieved.

[0090] (5) The monitoring detector according to (3), wherein the ultrasonic sensor 12 includes a piezoelectric element 121 formed directly on the inner wall of the outer cylinder part 11.

[0091] According to this structure, without using an adhesive that is worried about a decrease in adhesive force in a high-temperature environment, the state in which the ultrasonic sensor 12 is in contact with the outer cylinder part 11 of the monitoring detector 10 can be maintained. Therefore, long-term stable use of the ultrasonic sensor 12 in a high-temperature environment can be achieved.

[0092] (6) The monitoring detector according to (1) or (2), wherein the ultrasonic sensor 12 includes a pressing part 126 that applies a pressing load and is pressed by the pressing part 126 against the outer cylinder part 11.

[0093] According to this structure, even in a high-temperature environment where the melting or deterioration of the adhesive is a concern, the contact state between the ultrasonic sensor 12 and the outer cylinder part 11 can be maintained. Therefore, the ultrasonic sensor 12 can be used stably for a long time.

[0094] (7) The monitoring detector according to (3), wherein the ultrasonic sensor 12 includes a pressing part 126 that applies a pressing load and is pressed by the pressing part 126 against the outer cylinder part 11.

[0095] According to this structure, even in a high-temperature environment where the melting or deterioration of the adhesive is a concern, the contact state between the ultrasonic sensor 12 and the outer cylinder part 11 can be maintained. Therefore, the ultrasonic sensor 12 can be used stably for a long time.

[0096] (8)The monitoring detector according to (1), wherein the outer cylinder portion 11 simulates the superheater tube of a boiler, the double electrode sensor 13 includes a circular center electrode 133A and a circular second electrode 133B having a diameter larger than that of the center electrode 133A, and the thermocouple 14 is provided at the front end portion, the central portion, and the support portion on the outer side of the outer wall on the upstream side in the traveling direction of the combustion gas flow of the outer cylinder portion 11.

[0097] According to this structure, it is possible to provide a monitoring detector 10 capable of detecting both the wear amount and the corrosion state of the superheater tube of a boiler.

[0098] (9)The monitoring detector according to (2), wherein the cooling air supply system includes: a compressor, a receiver, a header, a flow control valve, and a pressure control valve, and the cooling air supply system supplies cooling air C to the inside of the outer cylinder portion 11.

[0099] According to this structure, it is possible to appropriately cool the outer cylinder portion 11 of the monitoring detector 10 exposed to high-temperature combustion gas. Therefore, it is possible to provide a monitoring detector 10 capable of stably detecting both the wear amount and the corrosion state even in a high-temperature environment.

[0100] (10)The monitoring detector according to (6), wherein the pressing portion 126 applies a pressing load for pressing the piezoelectric element against the outer cylinder portion 11.

[0101] According to this structure, even in a high-temperature environment where there is concern about a decrease in the adhesive force of the adhesive, it is possible to appropriately maintain the contact state between the ultrasonic sensor 12 and the outer cylinder portion 11. Therefore, the ultrasonic sensor 12 can be used stably for a long time.

[0102] (11)The monitoring detector according to (7), wherein the pressing portion 126 applies a pressing load for pressing the piezoelectric element against the outer cylinder portion 11.

[0103] According to this structure, even in a high-temperature environment where there is concern about a decrease in the adhesive force of the adhesive, it is possible to appropriately maintain the contact state between the ultrasonic sensor 12 and the outer cylinder portion 11. Therefore, the ultrasonic sensor 12 can be used stably for a long time.

[0104] (12)The monitoring detector according to any one of (1) to (11), wherein the double electrode sensor 13 includes: a fastening portion 131, a substrate portion 132, and a double electrode portion 133, the fastening portion 131 fastens both ends of the substrate portion 132 and fixes and supports the substrate portion 132 to the outer cylinder portion 11, the substrate portion 132 has electrical insulation, and the double electrode portion 133 is formed by two electrodes provided on the surface of the substrate portion 132 and not electrically connected to each other.

[0105] According to this structure, it is possible to measure the current value between the two electrodes generated by the melting of the adhered ash. Therefore, it is possible to provide the monitoring detector 10 that can stably detect both the wear amount and the corrosion state even in a high-temperature environment.

[0106] (13) In the monitoring detector according to (12), the substrate portion 132 includes a thermocouple.

[0107] According to this structure, the thermocouple can measure the temperature of the substrate portion 132. Therefore, it is possible to measure the current value between the two electrodes generated by the melting of the adhered ash and the temperature of the substrate portion 132, and to grasp the relationship between the current value between the two electrodes and the temperature of the substrate portion 132. Therefore, it is possible to provide the monitoring detector 10 that can stably detect both the wear amount and the corrosion state even in a high-temperature environment.

[0108] (14) In the monitoring detector according to (12), the double electrode portion 133 is connected to the sensor wire through a hole communicating with the internal cooling air flow path of the outer cylinder portion 11, and is connected to the processing device through the sensor wire.

[0109] According to this structure, it is possible to measure the current value between the two electrodes generated by the melting of the adhered ash. In addition, by laying the sensor wire inside the outer cylinder portion 11, the corrosion and deterioration of the sensor wire can be suppressed. Therefore, it is possible to provide the monitoring detector 10 that can stably detect both the wear amount and the corrosion state even in a high-temperature environment.

[0110] (15) A method for manufacturing a monitoring detector includes the following steps: a step of preparing a material for the outer cylinder portion 11 constituting the monitoring detector 10; a step of forming a piezoelectric element on the material; a step of assembling, pasting, and wiring the ultrasonic sensor 12; a step of welding the outer cylinder portion 11 of the monitoring detector 10; and a step of inserting a core into the inside of the outer cylinder portion 11.

[0111] According to this structure, it is possible to manufacture the monitoring detector 10 equipped with the ultrasonic sensor 12 that maintains close adhesion even in a state where the adhesive force in a high-temperature environment is feared to decrease. Therefore, it is possible to provide the monitoring detector 10 that can stably operate even in a high-temperature state.

[0112] (16) The manufacturing method of the monitoring detector according to (15). In the step of preparing materials, a specified material is used as the material for the outer cylinder part 11 constituting the monitoring detector 10, and an angled material subjected to beveling is prepared. In the step of wiring, the ultrasonic sensor 12 is installed on the inner surface of the angled material by an adhesive, a pressing load is applied to the ultrasonic sensor 12 by the pressing part 126, the signal wire is wired, and a thermocouple is installed. In the step of welding, the outer cylinder part 11 of the monitoring detector 10 is welded by aligning another angled material at the beveled position of the angled material. In the step of inserting, the core is arranged in alignment with the central axis of the outer cylinder part 11.

[0113] According to this structure, the monitoring detector 10 equipped with the ultrasonic sensor 12 can be appropriately manufactured. Therefore, the monitoring detector 10 that can operate stably even in a high-temperature state can be provided.

[0114] (17) The manufacturing method of the monitoring detector according to (15) or (16) further includes the step of manufacturing the ultrasonic sensor 12.

[0115] According to this structure, the monitoring detector 10 that can maintain the contact state between the ultrasonic sensor 12 and the outer cylinder part 11 even in a high-temperature environment can be manufactured. Therefore, the monitoring detector 10 that can operate stably even in a high-temperature state can be provided.

[0116] Above, the embodiments of the present disclosure have been described, but the embodiments are not limited by the content of the embodiments. In addition, the above-mentioned constituent elements include elements that can be easily conceived by those skilled in the art, substantially identical elements, and elements within the so-called equivalent range. Moreover, the above-mentioned constituent elements can be appropriately combined. And various omissions, replacements, or changes of the constituent elements can be made without departing from the gist of the above embodiments.

[0117] Description of Reference Numerals

[0118] 10 Monitoring detector

[0119] 11 Outer cylinder part

[0120] 12 Ultrasonic sensor

[0121] 121 Piezoelectric element

[0122] 122 Upper electrode

[0123] 123 Lead wire

[0124] 124 Saddle part

[0125] 125 Signal wire

[0126] 126 Pressing part

[0127] 127 Protection part

[0128] 128 Fastening part

[0129] 13 Dual - electrode sensor

[0130] 131 Fastening part

[0131] 132 Substrate part

[0132] 133 Dual - electrode part

[0133] 14 Thermocouple

[0134] 15 Core

Claims

1. A monitoring detector, comprising: A cylindrical outer cylinder portion, which is hollow inside; An ultrasonic sensor, provided on the inner wall side of the outer cylinder portion, and measuring the wall thickness of the outer cylinder portion through the reflected wave of ultrasonic waves from the outer wall of the outer cylinder portion; A double-electrode sensor, provided on the outer cylinder portion, and measuring the current value between two electrodes generated due to the melting of attached ash; and A thermocouple, provided on the outer cylinder portion, and measuring the temperature of the outer cylinder portion.

2. The monitoring detector according to claim 1, wherein, The monitoring detector further comprises a cooling air supply system for supplying cooling air to the inside of the outer cylinder portion.

3. The monitoring detector according to claim 1 or 2, wherein, A core for filling the hollow is further provided inside the outer cylinder portion.

4. The monitoring detector according to claim 1 or 2, wherein, The ultrasonic sensor comprises a piezoelectric element directly formed on the inner wall of the outer cylinder portion.

5. The monitoring detector according to claim 3, wherein, The ultrasonic sensor comprises a piezoelectric element directly formed on the inner wall of the outer cylinder portion.

6. The monitoring detector according to claim 1 or 2, wherein, The ultrasonic sensor comprises a pressing portion for applying a pressing load, and is pressed against the outer cylinder portion by the pressing portion.

7. The monitoring detector according to claim 3, wherein, The ultrasonic sensor comprises a pressing portion for applying a pressing load, and is pressed against the outer cylinder portion by the pressing portion.

8. The monitoring detector according to claim 1, wherein, The outer cylinder portion simulates the superheater tube of a boiler, The double-electrode sensor comprises a circular center electrode and a circular second electrode with a diameter larger than that of the center electrode, The thermocouple is provided at the front end portion, the central portion, and the support portion on the outer side of the outer wall on the upstream side in the traveling direction of the combustion gas flow of the outer cylinder portion.

9. The monitoring detector according to claim 2, wherein, The cooling air supply system has: a compressor, a receiver, a header, a flow regulating valve, and a pressure regulating valve, and the cooling air supply system supplies cooling air to the inside of the outer cylinder portion.

10. The monitoring detector according to claim 6, wherein, The pressing portion applies a pressing load for pressing the piezoelectric element against the outer cylinder portion.

11. The monitoring detector according to claim 7, wherein, The pressing portion applies a pressing load for pressing the piezoelectric element against the outer cylinder portion.

12. The monitoring detector according to claim 1, wherein, The double-electrode sensor comprises: a fastening portion, a substrate portion, and a double-electrode portion, The fastening portion fastens both ends of the substrate portion and fixedly supports the substrate portion on the outer cylinder portion, The substrate portion has electrical insulation, The double-electrode portion is formed by two electrodes provided on the surface of the substrate portion and not electrically connected to each other.

13. The monitoring detector according to claim 12, wherein, The substrate portion is provided with a thermocouple.

14. The monitoring detector according to claim 12, wherein, The double electrode part is connected to the sensor wire through a hole communicating with the cooling air flow path inside the outer cylinder part, and is connected to the processing device through the sensor wire.

15. A method for manufacturing a monitoring detector, comprising the following steps: A step of preparing a material for forming the outer cylinder part of the monitoring detector; A step of forming a piezoelectric element as a film on the material; A step of assembling, pasting, and wiring an ultrasonic sensor; A step of welding the outer cylinder part of the monitoring detector; and A step of inserting a core into the inside of the outer cylinder part.

16. The method for manufacturing a monitoring detector according to claim 15, wherein, in the step of preparing the material, a specified material is used as the material for forming the outer cylinder part of the monitoring detector, and an angled bar subjected to beveling is prepared; in the step of performing the wiring, the ultrasonic sensor is mounted on the inner surface of the angled bar by an adhesive, a pressing load is applied to the ultrasonic sensor by a pressing part, signal wires are wired, and a thermocouple is mounted; in the step of performing the welding, the outer cylinder part of the monitoring detector is welded by aligning other angled bars at the beveled position of the angled bar; in the step of performing the insertion, the core is arranged in alignment with the central axis of the outer cylinder part.

17. The method for manufacturing a monitoring detector according to claim 15 or 16, wherein, the method for manufacturing the monitoring detector further comprises a step of manufacturing an ultrasonic sensor.

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