Air pre-heater operation blockage fault identification and processing system

Abstract

The invention relates to the field of air pre-heater operation maintenance, in particular to an air pre-heater operation blockage fault recognition and processing system. Comprising a data acquisition module used for acquiring operation data of the air pre-heater, a data processing module connected with the data acquisition module, a central control module connected with the data processing module, an execution module connected with the central control module, and a display and alarm module connected with the data processing module and the central control module. A temperature sensor array and a pressure sensor group are combined, an artificial intelligence algorithm is adopted for data analysis and fault diagnosis, multiple processing modes such as online purging, air pre-heater switching and offline flushing are integrated, and the applicability is improved through the comprehensive fault processing mode; the system can monitor the operation state of the air pre-heater in real time, accurately identify the blockage fault, and timely take effective treatment measures, thereby ensuring the normal operation of equipment such as a boiler, and reducing the economic loss.

Description

Technical Field

[0001] The present invention relates to the field of operation and maintenance of air preheaters, and particularly to a system for identifying and handling operation blockage faults of air preheaters. Background Art

[0002] An air preheater (hereinafter referred to as an air preheater) is an important component in equipment such as boilers. Its function is to use the heat of the flue gas at the tail of the boiler to heat the air entering the boiler, thereby improving the thermal efficiency of the boiler. During the operation of the air preheater, due to the deposition of dust, corrosion products, and unburned substances in the flue gas on the heat exchange elements of the air preheater, the air preheater will be blocked. The blockage of the air preheater will increase the flow resistance of air and flue gas, reduce the heat exchange efficiency of the air preheater, and in severe cases, it will even affect the normal operation of the boiler, resulting in situations such as load reduction and shutdown of the unit, causing huge economic losses.

[0003] Currently, for the identification of air preheater blockage faults, most methods rely on manual regular inspections or monitoring of a single parameter such as the pressure difference between the inlet and outlet of the air preheater. Manual inspections have problems such as low efficiency, strong subjectivity, and inability to monitor in real time. When judging blockage faults only by monitoring the pressure difference between the inlet and outlet, due to the influence of various factors on the pressure difference change, there are defects such as a high misjudgment rate and inability to accurately locate the blockage position. In terms of handling blockage faults, methods such as offline flushing are usually adopted. This method requires shutdown operations, which will cause production interruptions, and the flushing effect is limited, and the blockage problem cannot be solved in a timely and effective manner.

[0004] Therefore, those skilled in the art have provided a system for identifying and handling operation blockage faults of air preheaters to solve the problems raised in the above background art. Summary of the Invention

[0005] To solve the above technical problems, the present invention provides a system for identifying and handling operation blockage faults of air preheaters, which solves the problems in the prior art such as low efficiency, strong subjectivity, and inability to monitor in real time through manual inspections; high misjudgment rate and inability to accurately locate the blockage position; offline flushing and other methods require shutdown operations, which will cause production interruptions, and the flushing effect is limited, and the blockage problem cannot be solved in a timely and effective manner.

[0006] It includes a data acquisition module for collecting operation data of the air preheater; the data acquisition module includes a temperature sensor array and a pressure sensor group. A data processing module is connected to the data acquisition module for receiving and processing the data transmitted by the data acquisition module; the data processing module includes a data receiving unit, a data analysis unit, and a fault diagnosis unit. A central control module is connected to the data processing module for receiving a fault diagnosis report and formulating a processing plan; the central control module includes a fault receiving unit, a decision-making unit, and an instruction sending unit. An execution module, connected to the central control module, for executing fault handling instructions; the execution module includes an online purging program, an air preheater switching program, and an offline flushing program; A display and alarm module, connected to the data processing module and the central control module, for displaying operating parameters and fault information and issuing alarms. The display and alarm module includes a display unit and an alarm unit.

[0007] Preferably, the temperature sensor array is evenly arranged along different heights and circumferential directions in the heat exchange element area of the air preheater for collecting temperature data at the location; the pressure sensor group is arranged at the inlet, outlet, and different internal positions of the air preheater for monitoring the pressure conditions at the inlet, outlet, and each internal area of the air preheater.

[0008] Preferably, the data receiving unit receives temperature data and pressure data; the data analysis unit uses an artificial intelligence algorithm. By establishing a normal operation data model of the air preheater, it compares the deviation between the collected data and the normal data model, combines preset fault judgment rules to judge whether the air preheater has a blockage fault, uses a thermal imaging analysis algorithm to locate the blockage area based on the temperature data distribution, and predicts the probability and time of future blockage of the air preheater according to historical data and current data; the fault diagnosis unit generates a fault diagnosis report containing the fault type, blockage location, blockage degree, and fault occurrence time according to the judgment result of the data analysis unit.

[0009] Preferably, the fault receiving unit receives the fault diagnosis report; the decision-making unit formulates a fault handling plan according to the fault diagnosis report and preset handling strategies. When the air preheater is slightly blocked, it starts the online purging program. When the blockage is relatively serious, it controls the switch to the standby air preheater for operation and starts the offline flushing program; the instruction sending unit sends the fault handling plan to the execution module in the form of an instruction.

[0010] Preferably, the online purging program includes a compressed air pipeline and multiple purging nozzles. The purging nozzles are arranged inside the air preheater and purge the heat exchange elements of the air preheater through the purging nozzles after receiving the online purging instruction; the air preheater switching program realizes the switching between the main air preheater and the standby air preheater; the offline flushing program includes a flushing water pump, a flushing water pipe, and a spray head. The flushing water pipe is arranged inside the air preheater. After the air preheater is switched to the standby air preheater for operation, the blocked air preheater is flushed through the spray head.

[0011] Preferably, the display unit displays the operating parameters of the air preheater, the fault diagnosis report, and the execution status of the fault handling plan in real time; the alarm unit issues an audible and visual alarm signal when the data processing module determines that the air preheater has a blockage fault, and sends the alarm information to relevant management personnel in the form of a text message or an email.

[0012] Preferably, the temperature sensor array is arranged at intervals of 1 meter in the height direction and at intervals of 30 degrees in the circumferential direction.

[0013] Preferably, one pressure sensor is provided in the air preheater every 5 meters for the pressure sensor group.

[0014] Preferably, after receiving the online purging instruction, the online purging program has a purging duration of 10 minutes.

[0015] Preferably, after the air preheater switching is completed, the offline flushing program has a flushing duration of 30 minutes.

[0016] Technical effects and advantages of the present invention: The present invention collects the operation data of the air preheater in multiple dimensions with a temperature sensor array and a pressure sensor group, and uses an artificial intelligence algorithm for data analysis and fault diagnosis. Different from the existing method of judging faults only through a single parameter, it has obvious innovation; At the same time, the system integrates various processing methods such as online purging, air preheater switching, and offline flushing, and automatically selects a suitable processing scheme according to different blockage situations. This comprehensive method of dealing with faults improves the applicability; Through thermal imaging analysis of the temperature data collected by the temperature sensor array, the blockage area can be accurately located, solving the problem that the existing technology cannot accurately determine the blockage position; Using the artificial intelligence algorithm to analyze multi-source data and predict faults improves the accuracy and timeliness of fault identification, and has outstanding substantive features and remarkable progress compared with traditional methods; The fault processing scheme of the system can automatically switch the processing method according to the blockage degree, realizing intelligent processing and overcoming the limitations of the existing processing methods.

[0017] This system can monitor the operation status of the air preheater in real time, accurately identify blockage faults, and take effective treatment measures in time, avoiding situations such as unit load reduction and shutdown caused by air preheater blockage, ensuring the normal operation of equipment such as boilers, improving production efficiency, and reducing economic losses.

[0018] The system is simple to operate and convenient to maintain, has strong practicability, and can be widely applied to various industrial fields using air preheaters. Description of the Drawings

[0019] Figure 1 is a flowchart of a system for identifying and handling blockage faults in the operation of an air preheater provided by an embodiment of the present application. Detailed Embodiments

[0020] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments of the present invention are given for the purpose of illustration and description, and are not exhaustive or limit the present invention to the disclosed form. Many modifications and variations are obvious to those of ordinary skill in the art. The embodiments are selected and described to better illustrate the principles and practical applications of the present invention, and enable those of ordinary skill in the art to understand the present invention and design various embodiments with various modifications suitable for specific purposes. Embodiment

[0021] Please refer to Figure 1 , in this embodiment, a system for identifying and handling the blockage fault of an air preheater is provided, including a data acquisition module for collecting the operation data of the air preheater. The data acquisition module includes a temperature sensor array and a pressure sensor group. The temperature sensor array is uniformly arranged along different heights and circumferential directions in the heat exchange element area of the air preheater for collecting the temperature data at the corresponding positions. The pressure sensor group is arranged at the inlet, outlet and different internal positions of the air preheater for monitoring the pressure conditions in the inlet, outlet and each internal area of the air preheater; a data processing module connected to the data acquisition module for receiving and processing the data transmitted by the data acquisition module. The data processing module includes a data receiving unit, a data analysis unit and a fault diagnosis unit. The data receiving unit receives the temperature data and pressure data. The data analysis unit uses an artificial intelligence algorithm. By establishing a normal operation data model of the air preheater, it compares the deviation between the collected data and the normal data model, and combines the preset fault judgment rules to judge whether the air preheater has a blockage fault. It uses a thermal imaging analysis algorithm to locate the blockage area according to the temperature data distribution, and predicts the probability and time of future blockage of the air preheater based on historical data and current data. The fault diagnosis unit generates a fault diagnosis report including the fault type, blockage position, blockage degree and fault occurrence time according to the judgment result of the data analysis unit; a central control module connected to the data processing module for receiving the fault diagnosis report and formulating a processing plan. The central control module includes a fault receiving unit, a decision-making unit and an instruction sending unit. The fault receiving unit receives the fault diagnosis report. The decision-making unit formulates a fault processing plan according to the fault diagnosis report and the preset processing strategy. When the air preheater is slightly blocked, it starts an online purging program. When the blockage is relatively serious, it controls the switch to the standby air preheater for operation and starts an offline flushing program. The instruction sending unit sends the fault processing plan to the execution module in the form of an instruction; An execution module, connected to the central control module, is used to execute fault handling instructions. The execution module includes an online purging program, an air preheater switching program, and an offline flushing program. The online purging program includes a compressed air pipeline and multiple purging nozzles. The purging nozzles are arranged inside the air preheater and blow the heat exchange elements of the air preheater through the purging nozzles after receiving the online purging instruction. The air preheater switching program realizes the switching between the main air preheater and the standby air preheater. The offline flushing program includes a flushing water pump, a flushing water pipe, and a nozzle. The flushing water pipe is arranged inside the air preheater, and after the air preheater is switched to the standby air preheater for operation, the blocked air preheater is flushed through the nozzle. A display and alarm module, connected to the data processing module and the central control module, is used to display operating parameters and fault information and issue an alarm. The display and alarm module includes a display unit and an alarm unit. The display unit displays the operating parameters of the air preheater, the fault diagnosis report, and the execution status of the fault handling solution in real time. The alarm unit emits an audible and visual alarm signal when the data processing module determines that the air preheater has a blockage fault, and sends the alarm information to relevant management personnel in the form of a text message or an email.

[0022] Among them, the temperature sensor array is arranged at intervals of 1 meter in the height direction and at intervals of 30 degrees in the circumferential direction. A pressure sensor is set every 5 meters inside the air preheater for the pressure sensor group. After the online purging program receives the online purging instruction, the purging duration is 10 minutes. After the air preheater switching is completed, the offline flushing process lasts for 30 minutes.

[0023] The usage process of the present invention is as follows: I. Installation and operation of the data acquisition module In the heat exchange element area of the air preheater, temperature sensors are uniformly installed at intervals of a certain distance (such as 1 meter) in the height direction and at intervals of a certain angle (such as 30 degrees) in the circumferential direction according to a predetermined plan to form a temperature sensor array. Pressure sensors are set at the inlet and outlet of the air preheater and at intervals of a certain distance (such as 5 meters) inside to form a pressure sensor group. During the operation of the air preheater, these sensors collect temperature and pressure data in real time and transmit the data to the data processing module through a data transmission line. II. Workflow of the data processing module After the data receiving unit receives the data transmitted by the data acquisition module, the data analysis unit first preprocesses the data to remove abnormal data and noise. Then, the processed data is compared with the pre-established normal operation data model of the air preheater. When the temperature data shows a local abnormal increase or decrease, and the pressure data shows that the differential pressure between the inlet and outlet increases beyond a preset threshold, the deviation degree is calculated through an artificial intelligence algorithm. In combination with the preset fault judgment rules, determine whether the air preheater has a blockage fault; If it is determined that the air preheater is blocked, use the thermal imaging analysis algorithm to analyze the temperature data collected by the temperature sensor array to determine the specific location and scope of the blocked area; At the same time, based on historical data and current data, predict the probability and time of future blockage of the air preheater; Finally, the fault diagnosis unit generates a fault diagnosis report and transmits the report to the central control module.

[0024] III. Decision-making and Instruction Sending of the Central Control Module After the fault receiving unit receives the fault diagnosis report, the decision-making unit formulates a fault handling plan according to the blockage degree and the preset handling strategy; If the blockage degree is relatively light, the decision-making unit issues an online purging instruction; If the blockage degree is relatively heavy, the decision-making unit first issues an air preheater switching instruction to switch the flue gas and air to the standby air preheater for operation, and then issues an offline flushing instruction; The instruction sending unit sends the formulated instructions to the execution module. IV. Action Execution of the Execution Module After the online purging program receives the online purging instruction, the compressed air pipeline is opened, and the compressed air blows the heat exchange elements of the air preheater through the purging nozzles, and stops after a certain period of time (such as 10 minutes); After the air preheater switching program receives the air preheater switching instruction, it switches the flow paths of the flue gas and air to the standby air preheater according to the predetermined program; After the air preheater switching is completed, the offline flushing program starts the flushing water pump, pressurizes the flushing water, and flushes the blocked air preheater through the nozzles. The flushing process lasts for a certain period of time (such as 30 minutes) until the deposits on the heat exchange elements are flushed clean. V. Operation of the Display and Alarm Module The display unit displays the operating parameters of the air preheater, the fault diagnosis report, and the execution status of the fault handling plan in real time; When the alarm unit receives the fault signal sent by the data processing module, it immediately issues an audible and visual alarm signal and sends the alarm information to the relevant management personnel; The management personnel can understand the details of the fault through the display unit and monitor and intervene in the fault handling process. Through the above specific implementation manners, the air preheater operation blockage fault identification and processing system of the present invention can effectively identify and process the blockage fault of the air preheater, and ensure the normal operation of the air preheater.

[0025] All the electrical components mentioned in this article are electrically connected to the external main controller and the 220V mains power supply. The main controller can be a conventional known device such as a computer for control. In the specific implementation manners of the present disclosure, the detailed descriptions of known functions and known components are omitted. To ensure the compatibility of the device, the operation means adopted are consistent with the parameters of market instruments.

[0026] In the solution, unless otherwise clearly specified and limited, terms such as "installation", "setting", "connection", "fixation", "swivel connection" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components or the interaction relationship between two components. Unless otherwise clearly limited, for those of ordinary skill in the art, the specific meanings of the above terms in this solution can be understood according to specific situations.

[0027] Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all embodiments. All other embodiments obtained by those of ordinary skill in the art and related fields based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention. Structures, devices, and operation methods not specifically described and explained in the present invention, unless otherwise specified and limited, are implemented according to the conventional means in the art.

Claims

1. An air preheater operation blockage fault identification and processing system, characterized in that: It includes a data acquisition module for collecting air preheater operation data; the data acquisition module includes a temperature sensor array and a pressure sensor group; A data processing module, connected to the data acquisition module, for receiving and processing data transmitted by the data acquisition module; the data processing module includes a data receiving unit, a data analysis unit and a fault diagnosis unit; A central control module, connected to the data processing module, for receiving fault diagnosis reports and formulating processing plans; the central control module includes a fault receiving unit, a decision-making unit and an instruction sending unit; An execution module, connected to the central control module, for executing fault handling instructions; the execution module includes an online purge program, an air preheater switching program and an offline flushing program; The display and alarm module is connected to the data processing module and the central control module, and is used to display operating parameters and fault information and issue an alarm. The display and alarm module includes a display unit and an alarm unit.

2. The air preheater operation blockage fault identification and processing system according to claim 1 is characterized in that: The temperature sensor array is evenly arranged at different heights and circumferential directions in the heat exchange element area of ​​the air preheater to collect temperature data at the location; the pressure sensor group is set at the inlet and outlet of the air preheater and different internal positions to monitor the pressure conditions of the inlet and outlet of the air preheater and various internal areas.

3. The air preheater operation blockage fault identification and processing system according to claim 2 is characterized in that: The data receiving unit receives temperature data and pressure data; the data analysis unit uses an artificial intelligence algorithm to establish a normal operation data model of the air preheater, compares the deviation between the collected data and the normal data model, and determines whether a blockage fault occurs in the air preheater in combination with a preset fault judgment rule, and uses a thermal imaging analysis algorithm to locate the blockage area according to the temperature data distribution, and predicts the probability and time of future blockage of the air preheater according to historical data and current data; The fault diagnosis unit generates a fault diagnosis report including the fault type, blockage location, blockage degree and fault occurrence time according to the judgment result of the data analysis unit.

4. The air preheater operation blockage fault identification and processing system according to claim 3 is characterized in that: The fault receiving unit receives a fault diagnosis report; the decision unit formulates a fault handling plan based on the fault diagnosis report and a preset handling strategy, starts an online purge program when the air preheater is slightly blocked, and controls switching to a standby air preheater and starts an offline flushing program when the blockage is more serious; the instruction sending unit sends the fault handling plan to the execution module in the form of an instruction.

5. The air preheater operation blockage fault identification and processing system according to claim 4 is characterized in that: The online purge program includes a compressed air pipeline and multiple purge nozzles. The purge nozzles are arranged inside the air preheater. After receiving the online purge instruction, the air preheater heat exchange element is purged through the purge nozzles; the air preheater switching program realizes the switching between the main air preheater and the standby air preheater; the offline flushing program includes a flushing water pump, a flushing water pipe and a nozzle. The flushing water pipe is arranged inside the air preheater. After the air preheater is switched to the standby air preheater, the blocked air preheater is flushed through the nozzle.

6. The air preheater operation blockage fault identification and processing system according to claim 1 is characterized in that: The display unit displays the operating parameters of the air preheater, fault diagnosis report and execution status of the fault handling plan in real time; the alarm unit sends out an audible and visual alarm signal when the data processing module determines that a blockage fault occurs in the air preheater, and sends the alarm information to relevant management personnel in the form of text messages or emails.

7. The air preheater operation blockage fault identification and processing system according to claim 2 is characterized in that: The temperature sensor array is arranged every 1 meter in the height direction and every 30 degrees in the circumferential direction.

8. The air preheater operation blockage fault identification and processing system according to claim 2 is characterized in that: The pressure sensor group is provided with a pressure sensor every 5 meters inside the air preheater.

9. The air preheater operation blockage fault identification and processing system according to claim 5 is characterized in that: After the online purge program receives the online purge instruction, the purge duration is 10 minutes.

10. The air preheater operation blockage fault identification and processing system according to claim 5, characterized in that: The offline flushing procedure is carried out after the air preheater is switched, and the duration of the flushing process is 30 minutes.

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