Boiler tube leakage prevention system, method, equipment and medium
By combining a distributed monitoring system with millimeter-level lidar and infrared thermal imager, the problem of accurate detection of boiler heat pipe deformation is solved, efficient and accurate leakage warning is achieved, and the risk of boiler accidents is reduced.
Patent Information
- Application Number
- CN202510903437.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-01
- Publication Date
- 2025-08-15
AI Technical Summary
The prior art lacks effective means to measure boiler heat pipe deformation caused by stress, especially under high temperature conditions, resulting in potential leakage risks and serious economic losses.
The combination of millimeter-level lidar and infrared thermal imager is adopted to monitor the deformation and temperature of the boiler furnace tube in real time through distributed deployment, and use data acquisition, analysis and early warning modules to make multi-parameter coordinated judgments, predict the probability of leakage and provide early warning.
It realizes efficient and accurate monitoring of boiler heat pipe deformation, improves monitoring range and accuracy, and reduces economic losses and safety risks caused by leakage.
Smart Images
Figure CN120488214A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of industrial detection, and in particular to a boiler tube leakage prevention system, method, equipment and medium. Background Art
[0002] The hazards posed by boiler heat pipe failures can be catastrophic. Once such an incident occurs, it invariably results in a boiler shutdown. In a large, high-pressure boiler, a single superheater tube burst can damage dozens or even hundreds of other intact tubes. Direct economic losses from shutdowns for maintenance, power rationing, and production can reach tens or even hundreds of millions of yuan, and can also result in serious personal injury. Some heat pipe failures are difficult for on-site operators or maintenance personnel to prevent, resulting in dozens of casualties at a time. Sometimes, these incidents occur repeatedly, leading to serious consequences.
[0003] Among the nine failure mechanisms of boiler heat pipes, high-temperature creep and fracture of the pipes due to stress is one of them. In addition to external forces such as internal pressure, deadweight, and support and hanger reaction forces, the loads acting on the pipes also include factors such as thermal expansion, contraction, and additional displacement of the endpoints, all of which can cause internal forces and deformation in the pipes. Broadly speaking, these factors are referred to as loads. The loads borne by boiler pipes are mainly the following: (1) Medium pressure, including the stable pressure under normal operating conditions, the pressure rise and fall during start-up and shutdown, and the higher pressure when the safety valve is started and during the water pressure test.
[0004] (2) Additional loads include the uniform load composed of the weight of the pipe itself, the internal medium, etc., and the local concentrated load caused by support and suspension.
[0005] (3) Thermal stress, including "stable thermal stress" caused by the temperature difference between the inner and outer walls of the same part of the pipe or the temperature difference between the walls of different parts of the pipe under normal operating conditions, "variable thermal stress" caused by the variable temperature difference of the pipe wall under variable operating conditions, and "alternating thermal stress" caused by the high frequency of wall temperature fluctuations in individual parts of the component. (4) Residual stress, including welding residual stress, expansion wire residual stress, etc.
[0006] The most likely effect of these loads on boiler heat pipes is deformation of the heat pipes, leading to creep, deformation or bursting.
[0007] However, there is currently no method for measuring stress-induced deformation of boiler heat pipes. The vast majority of deformation is caused by thermal stress, which is particularly prevalent in the context of deep peak shaving and co-firing. While there are methods for measuring stress and deformation using optical fibers, these are contact-based measurements performed at room temperature and pressure, and are not suitable for operation under high boiler temperatures. Summary of the Invention
[0008] The purpose of the present invention is to provide a boiler tube leakage prevention system, method, equipment and medium to solve the technical problem that the existing technology lacks corresponding detection means for boiler deformation caused by stress.
[0009] The present invention provides a boiler tube leakage prevention system, comprising: Millimeter-level laser radar, infrared thermal imager and host computer leakage warning module; The millimeter-level laser radar and infrared thermal imager are both connected to the host computer leakage warning module through communication lines.
[0010] A method for preventing boiler tube leakage is applied to the above system, and the method comprises the following steps: S1. Distributed deployment of boiler tube leakage prevention system; S2, obtain millimeter-level lidar data and infrared thermal imager data through the data acquisition submodule; S3. Use the data analysis submodule to make collaborative judgments on multiple parameters and predict the probability of boiler tube leakage when the parameters are abnormal. S4. Through the early warning submodule, early warning information is notified according to the leakage probability.
[0011] A storage medium stores instructions and data for implementing a boiler tube leakage prevention method.
[0012] A boiler tube leakage prevention device comprises: a processor and a storage medium; the processor loads and executes instructions and data in the storage medium to implement a boiler tube leakage prevention method.
[0013] The beneficial effects provided by the present invention are: 1. Millimeter-level precision laser radar and infrared thermal imager (displacement detection and temperature detection methods) are used simultaneously to detect boiler pipe deformation, realizing the monitoring of boiler heat pipe deformation caused by stress; 2. The system consists of three parts: a millimeter-level precision laser radar for monitoring furnace tube deformation, an infrared thermal imager for real-time monitoring of regional temperature, and a software system for analyzing and calculating the degree of furnace tube deformation, the probability of furnace tube leakage, and issuing early warnings, thereby improving monitoring efficiency. 3. The probability calculation method for leakage in each area of the boiler pipeline is determined by regional temperature difference data and local displacement data, which improves monitoring accuracy; 4. Distributed deployment: Since boiler tubes are distributed in rows and cover a large area, the monitoring range of one set of equipment is often unable to cover all boiler tubes. Therefore, a distributed deployment method is adopted to connect data from multiple sets of equipment to the system, and the system integrates the data to present data from the entire monitoring range, thereby increasing the scope of application. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 It is a schematic flow chart of the method of the present invention; Figure 2 This is a structural diagram of the host computer warning module; Figure 3 It is a schematic flow chart of the method of the present invention; Figure 4 It is a working diagram of the hardware device of the present invention. DETAILED DESCRIPTION
[0015] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described below with reference to the accompanying drawings.
[0016] Before formally explaining the present invention, the scheme of the present invention is first generally explained for easy understanding.
[0017] Please refer to Figure 1 , Figure 1 It is a structural diagram of the system of the present invention.
[0018] The present invention provides a boiler tube leakage prevention system, comprising: Millimeter-level laser radar, infrared thermal imager and host computer leakage warning module; The millimeter-level laser radar and infrared thermal imager are both connected to the host computer leakage warning module through communication lines.
[0019] It's important to note that millimeter-level radar operates in the millimeter wave band. Millimeter waves typically refer to frequencies between 30 and 300 GHz (wavelengths of 1 to 10 mm). Millimeter waves have wavelengths between microwaves and centimeter waves, so millimeter-wave radar combines the advantages of both microwave and optoelectronic radar.
[0020] Compared to centimeter-wave seekers, millimeter-wave seekers are smaller, lighter, and have higher spatial resolution. Compared to optical seekers such as infrared, laser, and television, millimeter-wave seekers are more capable of penetrating fog, smoke, and dust, and operate in all weather conditions (except during heavy rain). Furthermore, millimeter-wave seekers have superior anti-interference and anti-stealth capabilities compared to other microwave seekers.
[0021] An infrared thermal imager utilizes infrared thermal imaging technology to detect infrared radiation from an object and, through signal processing and photoelectric conversion, convert the object's temperature distribution into a visual image. The infrared thermal imager precisely quantifies the actual heat detected, creating a real-time surface image of the entire object. This allows accurate identification of areas suspected of heating faults. It should be noted that the millimeter-level lidar is installed inside the boiler to monitor the deformation of the boiler tubes in real time.
[0022] In the present invention, millimeter-level precision laser radar and infrared thermal imager (displacement detection and temperature detection methods) are simultaneously used to detect boiler pipe deformation; It should be noted that the millimeter-level laser radar is installed inside the boiler to monitor the deformation of the boiler tubes in real time.
[0023] It should be noted that the infrared thermal imager is installed inside the boiler to monitor the furnace tube temperature in real time.
[0024] Please refer to Figure 2 , Figure 2 This is a structural diagram of the host computer early warning module; the host computer leakage early warning module includes: a data acquisition submodule, a data analysis submodule and an early warning submodule.
[0025] As an embodiment, the data acquisition submodule is used to collect millimeter-level laser radar data and infrared thermal imager data; The data analysis submodule is used to analyze millimeter-level lidar data and infrared thermal imager data; The early warning submodule is used to send early warning information according to the analysis results.
[0026] Please refer to Figure 3 , Figure 3 It is a schematic flow chart of the method of the present invention.
[0027] A method for preventing boiler tube leakage is applied to the above system, and the method comprises the following steps: S1. Distributed deployment of boiler tube leakage prevention system; It should be noted that since boiler tubes are distributed in rows and cover a large area, the monitoring range of one set of equipment is often unable to cover all boiler tubes. Therefore, a distributed deployment method is adopted to connect data from multiple sets of equipment to the system, and the system integrates the data to present data from the entire monitoring range.
[0028] S2, obtain millimeter-level lidar data and infrared thermal imager data through the data acquisition submodule; S3. Use the data analysis submodule to make collaborative judgments on multiple parameters and predict the probability of boiler tube leakage when the parameters are abnormal. S4. Through the early warning submodule, early warning information is notified according to the leakage probability.
[0029] It should be noted that the boiler leakage probability prediction is performed when the multi-parameter collaborative judgment satisfies any of the following conditions: Deformation-temperature correlation anomaly: When the local deformation obtained by millimeter-level lidar δ > δ th And the temperature difference of the corresponding area obtained by the infrared thermal imager Δ T >Δ T th When the boiler leaks, the probability prediction is carried out; Warning of worsening trend: when deformation accelerates d ² δ / dt ²> a max or temperature gradient rate When the boiler leaks, the probability prediction is carried out; Distributed data federation: Among the adjacent monitoring units of the boiler, unit A is deformed δ A > k·δ B And the temperature of unit B T B > T A +Δ T safe When the boiler leaks, the probability prediction is carried out; in, δ th is the preset local deformation threshold; Δ T th is the preset temperature difference threshold; a max is the preset maximum value of deformation acceleration; v max is the preset maximum value of the temperature gradient change rate; k is the deformation difference coefficient, which is an empirical value; Δ T safe is the preset joint temperature safety threshold.
[0030] It should be noted that the calculation formula for the boiler tube leakage probability in step S3 is as follows:
[0031] in, is the real-time deformation; is the maximum deformation; is the temperature gradient; is the maximum temperature gradient; 、 、 is the weight coefficient, and its sum is 1; is the nonlinear amplification exponent.
[0032] It should be noted that the various preset values or thresholds mentioned above can be dynamically adjusted and set by the data analysis submodule according to the boiler operating load conditions.
[0033] It should be noted that the notification method in the present invention can be carried out by telephone, email, text message, alarm (vibration and sound) and other related methods.
[0034] The present invention provides a specific embodiment as follows: In the high-temperature superheater area of a 600MW unit boiler in a power plant, three sets of monitoring devices were deployed in a distributed manner (covering the left, middle, and right sides of the boiler tubes). Each set of devices includes: Millimeter-level laser radar: installed 0.5m above the superheater tube bank, with a scanning frequency of 10Hz and a measurement accuracy of ±0.3mm; Infrared thermal imager: coaxially installed with the radar, with a resolution of 640×480 and a temperature measurement range of 300℃–1200℃.
[0035] Upper computer leakage warning module: deployed on the power plant DCS system server; The data acquisition submodule obtains in real time: LiDAR data: pipe row deformation δ (unit: mm), infrared data: pipe wall temperature matrix T(x,y) (unit: °C); for example, deformation δ = 1.85 mm (historical baseline value 1.0 mm), temperature gradient (Safety threshold 30℃ / m).
[0036] The data analysis submodule automatically sets the threshold value according to the current working conditions:
[0037] Perform multi-parameter collaborative judgment, for example, if conditions 1 and 2 are met: Condition 1: δ=1.85> δ th =1.2 and → Trigger prediction; Condition 2: Deformation acceleration d ² δ / dt ²=0.15mm / s²> a max =0.1mm / s², additional risk mark; Probability of leakage:
[0038] The parameter settings at this time are as follows: Weight distribution ( α =0.6, γ =0.3, λ =0.1): Focus on deformation risk under high load conditions; Cumulative creep =2.1: integral of the deformation rate over the past 72 hours.
[0039] The early warning submodule performs graded responses: When the probability is >30%, a secondary warning is triggered: An audible and visual alarm and a text message were sent to the control room to notify the engineer: "The risk of leakage of the right superheater tube is 36.8%. It is recommended to reduce the load for inspection."
[0040] See Figure 4 , Figure 4 4 is a schematic diagram of the working of the hardware device of an embodiment of the present invention, wherein the hardware device specifically includes: a boiler tube leakage prevention device 401, a processor 402 and a storage medium 403.
[0041] A boiler tube leakage prevention device 401: The boiler tube leakage prevention device 401 implements the boiler tube leakage prevention method.
[0042] Processor 402: The processor 402 loads and executes the instructions and data in the storage medium 403 to implement the boiler tube leakage prevention method.
[0043] Storage medium 403: The storage medium 403 stores instructions and data; the storage medium 403 is used to implement the boiler tube leakage prevention method.
[0044] The beneficial effects of the present invention are: 1. Millimeter-level precision laser radar and infrared thermal imager (displacement detection and temperature detection methods) are used simultaneously to detect boiler pipe deformation, realizing the monitoring of boiler heat pipe deformation caused by stress; 2. The system consists of three parts: a millimeter-level precision laser radar for monitoring furnace tube deformation, an infrared thermal imager for real-time monitoring of regional temperature, and a software system for analyzing and calculating the degree of furnace tube deformation, the probability of furnace tube leakage, and issuing early warnings, thereby improving monitoring efficiency. 3. The probability calculation method for leakage in each area of the boiler pipeline is determined by regional temperature difference data and local displacement data, which improves monitoring accuracy; 4. Distributed deployment: Since boiler tubes are distributed in rows and cover a large area, the monitoring range of one set of equipment is often unable to cover all boiler tubes. Therefore, a distributed deployment method is adopted to connect data from multiple sets of equipment to the system, and the system integrates the data to present data from the entire monitoring range, thereby increasing the scope of application.
[0045] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.
Claims
1. A boiler tube leakage prevention system, characterized by: include: Millimeter-level laser radar, infrared thermal imager and host computer leakage warning module; The millimeter-level laser radar and infrared thermal imager are both connected to the host computer leakage warning module through communication lines.
2. A boiler tube leakage prevention system according to claim 1, characterized in that: The millimeter-level laser radar is installed inside the boiler to monitor the deformation of the boiler tubes in real time.
3. The boiler tube leakage prevention system according to claim 1, characterized in that: The infrared thermal imager is installed inside the boiler and is used to monitor the furnace tube temperature in real time.
4. The boiler tube leakage prevention system according to claim 1, characterized in that: The upper computer leakage warning module includes: a data acquisition submodule, a data analysis submodule and a warning submodule.
5. The boiler tube leakage prevention system according to claim 4, characterized in that: The data acquisition submodule is used to collect millimeter-level lidar data and infrared thermal imager data; The data analysis submodule is used to analyze millimeter-level lidar data and infrared thermal imager data; The early warning submodule is used to send early warning information according to the analysis results.
6. A method for preventing boiler tube leakage, applied to the system according to any one of claims 1 to 5, characterized in that: The method comprises the following steps: S1. Distributed deployment of boiler tube leakage prevention system; S2, obtain millimeter-level lidar data and infrared thermal imager data through the data acquisition submodule; S3. Use the data analysis submodule to make collaborative judgments on multiple parameters and predict the probability of boiler tube leakage when the parameters are abnormal. S4. Through the early warning submodule, early warning information is notified according to the leakage probability.
7. A method for preventing boiler tube leakage according to claim 6, characterized in that: The multi-parameter collaborative judgment is performed to predict the boiler leakage probability if any of the following conditions are met: Deformation-temperature correlation anomaly: When the local deformation obtained by millimeter-level lidar δ > δ th And the temperature difference of the corresponding area obtained by the infrared thermal imager Δ T >Δ T th When the boiler leaks, the probability prediction is carried out; Warning of worsening trend: When deformation accelerates d ² δ / dt ²> a max or temperature gradient rate When the boiler leaks, the probability prediction is carried out; Distributed data federation: Among the adjacent monitoring units of the boiler, unit A is deformed δ A > k·δ B And the temperature of unit B T B > T A +Δ T safe When the boiler leaks, the probability prediction is carried out; in, δ th is the preset local deformation threshold; Δ T th is the preset temperature difference threshold; a max is the preset maximum value of deformation acceleration; v max is the preset maximum value of the temperature gradient change rate; k is the deformation difference coefficient, which is an empirical value; Δ T safe is the preset joint temperature safety threshold.
8. A method for preventing boiler tube leakage according to claim 7, characterized in that: The boiler tube leakage probability calculation formula in step S3 is as follows: in, is the real-time deformation; is the maximum deformation; is the temperature gradient; is the maximum temperature gradient; 、 、 is the weight coefficient, and its sum is 1; is the nonlinear amplification exponent.
9. A storage medium, characterized in that: The storage medium stores instructions and data for implementing a boiler tube leakage prevention method as described in claims 6 to 8.
10. A boiler tube leakage prevention device, characterized by: include: A processor and a storage medium; the processor loads and executes instructions and data in the storage medium to implement a boiler tube leakage prevention method as described in claims 6 to 8.