Coal mill pulverized coal pipe powder leakage alarm system and method

Abstract

The invention relates to the technical field of coal mill powder leakage monitoring, in particular to a coal mill pulverized coal pipe powder leakage alarm system and method. According to the pulverized coal leakage alarm system for the pulverized coal pipe of the coal mill, a plurality of particulate matter sensors are used for detecting the particulate matter concentration of the area outside the pulverized coal pipe in real time and generating corresponding concentration data; the control processing unit is in communication connection with the plurality of particulate matter sensors and is used for receiving and processing the concentration data in real time and comparing the concentration data with an internal preset concentration threshold value; and the sound-light alarm module is in communication connection with the control processing unit and is used for sound alarm and light indication. The environment outside the pulverized coal pipe is continuously and automatically monitored in real time through the particulate matter sensor, signals can be quickly captured at the initial stage of pulverized coal leakage, and the problem of lag caused by traditional manual inspection is thoroughly solved. The leakage point is accurately positioned, the operation and maintenance efficiency is greatly improved, and the number or position of the specific pipe section where leakage occurs is accurately indicated through the unique number of the sensor.

Description

Technical Field

[0001] This invention relates to the field of coal mill leakage monitoring technology, and in particular to a coal mill pulverized coal pipe leakage alarm system and method. Background Technology

[0002] In coal-fired power plants, the coal mill is the core equipment of the pulverizing system, responsible for grinding raw coal into fine powder, which is then transported to the boiler furnace for combustion via pulverized coal pipelines. Currently, for example, the HP1003 bowl-type medium-speed coal mill used by Huaneng Taicang Power Plant is typically equipped with multiple pulverized coal pipelines (e.g., 6) per unit. During long-term operation, the pipe walls gradually thin due to the continuous erosion and wear of the pulverized coal, which may eventually lead to pulverized coal leakage.

[0003] If a pulverized coal leak occurs and is not detected and dealt with in a timely manner, a large amount of pulverized coal will accumulate around the equipment. Due to the flammable and explosive nature of pulverized coal, it can easily spontaneously combust under suitable conditions, even causing a fire, seriously threatening the safe and stable operation of the power plant. Currently, monitoring of pulverized coal pipeline leaks mainly relies on regular on-site inspections by operators. This method has significant time lag, cannot achieve real-time monitoring and early warning, and is difficult to detect initial leaks in time, thus creating potential safety hazards.

[0004] Therefore, the existing technology lacks a system that can monitor coal powder pipeline leaks in real time and automatically and provide timely alarms, resulting in blind spots in coal powder leak prevention and control in power plants. There is an urgent need to develop a coal powder pipeline leak alarm system with a reasonable structure, rapid response, and high reliability to improve the safety management level of power plants. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the problems of the inability to monitor and warn of coal powder leakage in the coal mill tube in real time in the prior art.

[0006] To solve the above-mentioned technical problems, the present invention provides a coal mill pulverized coal pipe leakage alarm system, comprising: Multiple particulate matter sensors are arranged on the outer wall of the coal powder tube of the coal mill to detect the particulate matter concentration in the area outside the coal powder tube in real time and generate corresponding concentration data. The control and processing unit is communicatively connected to the plurality of particulate matter sensors, and is used to receive and process the concentration data in real time, and compare the concentration data with an internally preset concentration threshold. When the concentration data reported by the particulate matter sensor continues to exceed the preset concentration threshold, an alarm trigger signal is generated. The audible and visual alarm module is communicatively connected to the control and processing unit and is used for audible alarms and visual indications.

[0007] Preferably, the plurality of particulate matter sensors are arranged linearly at intervals along the coal powder flow direction of a single coal powder pipe, and are arranged on the outer wall of the weak area of ​​the coal powder pipe where wear or weld cracking occurs.

[0008] Preferably, when generating an alarm trigger signal, the control processing unit analyzes the identification information of the particulate matter sensor that triggered the alarm based on the mapping relationship between sensor identifiers and physical locations, and determines and outputs the number or location of the powder leakage area.

[0009] Preferably, the control processing unit includes a CPU module and an I / O module connected to each other; the I / O module is responsible for acquiring analog or digital signals from all particulate matter sensors, and the CPU module is responsible for performing data comparison, logical judgment, and issuing control commands.

[0010] Preferably, the control processing unit further includes: receiving and storing the preset concentration threshold through a human-machine interface; periodically storing historical concentration data and alarm event records; and communicating with the upper-level monitoring system to upload alarm status and device information.

[0011] Preferably, the audible and visual alarm module includes a photon sign or a graphical human-machine interface, used to visually display the number or location description of the powder leakage area when the alarm is triggered.

[0012] Preferably, the audible and visual alarm module is installed in the central control room or the area where the operation duty officer is stationed. Its audible alarm has different tones or voice prompts to distinguish the alarm level, and its light indicator is a flashing red light.

[0013] This invention also provides a method for alarming coal powder leakage from a coal mill's pulverized coal pipe, comprising: Using particulate matter sensors, real-time data on particulate matter concentration in the area is collected. Based on the particulate matter concentration data, a comparison and analysis are performed with a preset concentration threshold; when the concentration data is abnormal, the control processing unit generates an alarm trigger signal and locks the corresponding sensor number. Based on the alarm trigger signal, an audible and visual alarm is activated, and the specific powder leakage pipe section number is indicated.

[0014] Preferably, the real-time acquisition of particulate matter concentration data in the area using a particulate matter sensor includes: Multiple monitoring points were arranged along the outer wall of the multiple pulverized coal pipes of the coal mill; The particulate matter concentration change around the pulverized coal pipe is monitored by a particulate matter sensor installed at the monitoring point. When the particulate matter concentration at a specific monitoring point exceeds a preset safety threshold, it is determined that a pulverized coal leakage has occurred in the pulverized coal pipeline section corresponding to that monitoring point, and an alarm signal containing location information is generated.

[0015] Preferably, the step of determining that a pulverized coal leakage has occurred in the pulverized coal pipe section corresponding to a specific monitoring point when the particulate matter concentration at a specific monitoring point exceeds a preset safety threshold, and generating an alarm signal containing location information, includes: Start the image acquisition equipment located near the monitoring point to capture on-site images; The captured scene footage, along with the alarm signal and location information, will be sent to the monitoring center.

[0016] The technical solution of the present invention has the following advantages compared with the prior art: This invention discloses a coal mill pulverized coal pipe leakage alarm system and method. Through a particulate matter sensor, it performs real-time, uninterrupted automatic monitoring of the external environment of the pulverized coal pipe, rapidly capturing signals in the early stages of pulverized coal leakage, completely solving the problem of the lag associated with traditional manual inspections. Precisely locating the leak point greatly improves operation and maintenance efficiency. The unique sensor number accurately indicates the specific pipe section number or physical location of the leak. Operators or maintenance personnel can directly address the problem on-site, saving time spent searching through dense pipelines, resulting in an order-of-magnitude improvement in fault handling efficiency and a reduction in equipment downtime. The historical concentration data and alarm events recorded by the system can serve as important evidence for equipment condition assessment. Analysis of data trends can reveal the slow deterioration process before reaching the alarm threshold, thereby predicting the health status of the coal mill pulverized coal pipe and scheduling maintenance in advance for preventative maintenance. Attached Figure Description

[0017] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein: Figure 1 This is a structural diagram of a coal mill pulverized coal pipe leakage alarm system provided by the present invention; Figure 2 This is a schematic diagram of the arrangement of particulate matter sensors on the coal powder tube wall of a coal mill; Figure 3 This is a flowchart of a coal mill pulverized coal pipe leakage alarm method provided by the present invention. Detailed Implementation

[0018] The core of this invention is to provide a coal pulverizer pulverizer pipe leakage alarm system. Through particulate matter sensors, the system can perform real-time and uninterrupted automatic monitoring of the external environment of the pulverizer pipe. It can quickly capture signals in the early stage of pulverizer leakage, accurately locate the leakage point, and improve operation and maintenance efficiency.

[0019] To enable those skilled in the art to better understand the present invention, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please refer to Figure 1 , Figure 1 The present invention provides a structural diagram of a coal mill pulverized coal pipe leakage alarm system; the specific operation steps are as follows: Multiple particulate matter sensors are arranged on the outer wall of the coal powder tube of the coal mill to detect the particulate matter concentration in the area outside the coal powder tube in real time and generate corresponding concentration data. Multiple particulate matter sensors are arranged linearly at intervals along the coal powder flow direction of a single coal powder pipe, and are placed on the outer wall of the weak area of ​​the coal powder pipe where wear or weld cracking occurs.

[0021] In one embodiment, such as Figure 2 As shown, several particulate matter sensors are arranged on the outer wall of the pulverized coal pipe, with each sensor arranged sequentially every 10m along the pulverized coal flow direction, providing particulate matter concentration data for that area.

[0022] The control and processing unit is communicatively connected to the plurality of particulate matter sensors, and is used to receive and process the concentration data in real time, and compare the concentration data with an internally preset concentration threshold. When the concentration data reported by the particulate matter sensor continues to exceed the preset concentration threshold, an alarm trigger signal is generated. Specifically, when generating an alarm trigger signal, the control processing unit analyzes the identification information of the particulate matter sensor that triggered the alarm based on the mapping relationship between sensor identifiers and physical locations, and determines and outputs the number or location of the powder leakage area. The control processing unit includes an interconnected CPU module and an I / O module; the I / O module is responsible for acquiring analog or digital signals from all particulate matter sensors, and the CPU module is responsible for performing data comparison, logical judgment, and issuing control commands.

[0023] The control processing unit also includes: receiving and storing the preset concentration threshold through a human-machine interface; periodically storing historical concentration data and alarm event records; and communicating with the upper-level monitoring system to upload alarm status and equipment information.

[0024] In one embodiment, the CPU module and I / O (input / output) module are the core control components of the alarm system for coal powder leakage in the coal mill's pulverized coal pipe. They collect particulate matter concentration data from the particulate matter sensor in real time. When the particulate matter concentration data exceeds a set value, an audible and visual alarm is issued to the operator, along with the number of the leakage area, helping the operator quickly identify the leakage area on site. The CPU module also undertakes tasks such as setting setpoints, data storage, action event recording, human-machine communication, alarm signal output, and confirmation.

[0025] The audible and visual alarm module is communicatively connected to the control and processing unit and is used for audible alarms and visual indications.

[0026] Specifically, the sound and light alarm module includes a photon sign or a graphical human-machine interface, which is used to visually display the number or location description of the powder leakage area when the alarm is triggered; The audible and visual alarm module is installed in the central control room or the area where the operation staff are stationed. Its audible alarm has different tones or voice prompts to distinguish the alarm level, and its light indicator is a flashing red light.

[0027] This embodiment provides a coal pulverizer pulverized coal pipe leakage alarm system. It uses particulate matter sensors to perform real-time, uninterrupted automatic monitoring of the external environment of the pulverized coal pipe, enabling rapid detection of signals in the early stages of a pulverized coal leak, completely solving the problem of the lag associated with traditional manual inspections. Precisely locating the leak point greatly improves operation and maintenance efficiency. The unique sensor number accurately indicates the specific pipe section number or physical location of the leak. Operators or maintenance personnel can directly address the problem on-site, saving time spent searching through dense pipelines, resulting in an order-of-magnitude improvement in fault handling efficiency and a reduction in equipment downtime. The historical concentration data and alarm events recorded by the system can serve as important evidence for equipment condition assessment. Analysis of data trends can reveal the slow deterioration process before reaching the alarm threshold, thereby predicting the health status of the coal pulverizer pulverized coal pipe and scheduling maintenance in advance for preventative maintenance.

[0028] like Figure 3 As shown, Figure 3 A flowchart of a coal mill pulverized coal pipe leakage alarm method provided by the present invention is as follows: Step S301: Use a particulate matter sensor to collect particulate matter concentration data of the area in real time; Specifically, multiple monitoring points are arranged along the outer wall of the multiple pulverized coal pipes of the coal mill; The particulate matter concentration change around the pulverized coal pipe is monitored by a particulate matter sensor installed at the monitoring point. When the particulate matter concentration at a specific monitoring point exceeds a preset safety threshold, it is determined that a pulverized coal leakage has occurred in the pulverized coal pipeline section corresponding to that monitoring point, and an alarm signal containing location information is generated.

[0029] Step S302: Based on the particulate matter concentration data, compare and analyze it with a preset concentration threshold; when the concentration data is abnormal, the control processing unit generates an alarm trigger signal and locks the corresponding sensor number; Specifically, the image acquisition equipment located near the monitoring point is activated to capture on-site images; the captured on-site images, along with the alarm signal and location information, are sent to the monitoring center.

[0030] Step S303: Based on the alarm trigger signal, activate the audible and visual alarm and indicate the specific powder leakage pipe section number.

[0031] This embodiment provides a method for alarming coal powder leakage in a coal mill's pulverized coal pipe. It utilizes a particulate matter sensor to perform real-time, uninterrupted automatic monitoring of the external environment of the pulverized coal pipe, enabling rapid signal detection in the early stages of leakage and completely eliminating the lag issues associated with traditional manual inspections. Precise leak location significantly improves operational efficiency. The sensor's unique identifier accurately indicates the specific pipe section number or physical location of the leak. Operators or maintenance personnel can directly address the problem, saving time spent searching through dense pipelines, resulting in a significant increase in fault handling efficiency and reduced equipment downtime. The system records historical concentration data and alarm events, which can serve as crucial information for equipment condition assessment. Analysis of data trends reveals the slow deterioration process before reaching alarm thresholds, allowing for prediction of the pulverized coal pipe's health status and enabling proactive maintenance planning.

[0032] Based on the above embodiments, this embodiment provides a detailed description of a coal pulverizer pulverized coal pipe leakage alarm system, as follows: The following explanation uses an HP1003 coal mill equipped with six pulverized coal pipes as an example. Since these six pulverized coal pipes converge in their path from the coal mill outlet to the boiler burner, the monitoring focus is placed on this area.

[0033] Sensor placement: The PM2008 laser dust sensor was selected as the particulate matter sensor. This sensor features high measurement accuracy and fast response speed, and is encapsulated in an explosion-proof metal housing.

[0034] On the outer wall of each pulverized coal pipe, select an installation point every 10 meters along the flow direction of the pulverized coal. Use a special stainless steel clamp to firmly fix the sensor to the pipe wall, ensuring that the sensor detection window faces the gap area between the pipes for optimal detection of leaking pulverized coal.

[0035] All sensors are uniformly coded and entered into the system according to the rule of "coal mill number-pipeline number-serial number". For example, the sensor installed on coal mill #1, pipeline A, 10 meters from the outlet is numbered "1A01".

[0036] Control processing unit: The core of this unit uses a Siemens S7-1200 series PLC (programmable logic controller). The CPU1214C module serves as the CPU module, responsible for logic operations and system control; the matching SM1231 analog input module serves as the I / O module, used to receive 4-20mA analog current signals from all particulate matter sensors.

[0037] Operators can easily set parameters via a touchscreen connected to the PLC (such as the Siemens KTP700 Basic), for example, setting the alarm concentration threshold to 10 mg / m³. This touchscreen also displays real-time concentrations at each measuring point, stores data, queries action event records, and confirms alarm signals.

[0038] The PLC communicates with the power plant's upstream monitoring system (such as DCS) via its integrated PROFINET interface, uploading alarm status and key data.

[0039] Alarm module: The audible and visual alarm (such as the HD-110B model) is installed on the main control panel in the central control room. When it receives an alarm trigger signal from the PLC, it will emit a high-frequency buzzer and activate a flashing red LED light to immediately attract the attention of the operators.

[0040] At the same time, an alarm window will pop up on the large screen display (photon board) in the control room, clearly displaying text information, such as: "Alarm: Particulate matter concentration at point 1A01 exceeds the standard!", thus directly providing the number of the powder leakage area and guiding the operators to quickly locate it.

[0041] Workflow: After the system is powered on, each sensor continuously monitors the concentration of coal powder in the environment and transmits the signal to the PLC.

[0042] The PLC periodically scans all input data and compares it with preset thresholds.

[0043] If sensor "1A01" detects a concentration that is above 10 mg / m³ for 3 consecutive seconds, the PLC will determine that powder leakage has occurred at that location.

[0044] The PLC then sends an alarm trigger signal to the audible and visual alarm and the large screen in the central control room, and records an action event containing the time, location, and concentration.

[0045] After hearing the alarm and seeing the alarm at point "1A01", the operators can immediately notify the on-site inspection personnel to go to the A pipeline of #1 coal mill 10 meters from the outlet to confirm and handle the situation. At the same time, the operation of the coal mill can be remotely stopped in an emergency to prevent the leakage from spreading.

[0046] Based on the above embodiments, this embodiment adds remote notification, image verification, and system self-test functions, as detailed below: System enhancements: A 4G / 5G wireless communication module is added to the control processing unit, which is connected to the PLC's serial port.

[0047] At key locations in the pulverized coal pipe gallery, network-connected high-definition PTZ cameras are pre-installed as image acquisition devices, and these cameras can be linked with the alarm system.

[0048] Enhanced workflow: When the PLC triggers an alarm, in addition to activating the local audible and visual alarm, it will also perform two additional actions: a. Through the wireless communication module, alarm SMS or App push information is sent to the smartphones (mobile terminals) of the shift leader and relevant maintenance personnel. The information content includes "coal mill pulverized coal pipe leakage alarm, point: 1A01".

[0049] b. Send control commands to the network HD PTZ camera located near point "1A01" via the communication network, so that it can automatically rotate to the preset position, capture on-site images of the leak area, and upload the captured images or short video streams along with alarm information to the server of the remote monitoring center.

[0050] Whether in the control room or via mobile phone, operators can see real-time images of the leak site, remotely verifying the authenticity of the alarm and assessing the severity of the leak, providing the most direct basis for making the most appropriate emergency response decisions (such as whether to shut down the boiler immediately).

[0051] Self-test function implementation: A periodic self-test routine was written in the PLC program. This program sends a specific self-test command to all connected particulate matter sensors every 24 hours.

[0052] A normal sensor will return a response signal within a preset range. If a sensor does not respond or returns an abnormal signal, the PLC will generate a "sensor failure" warning message on the touch screen and record it in the event log, prompting maintenance personnel to check or replace the sensor. This ensures the integrity of the monitoring network and avoids monitoring blind spots caused by sensor failure.

[0053] Preventative maintenance applications: The system stores historical concentration data from all monitoring points on a long-term, timed basis. Maintenance engineers can periodically retrieve this data to generate concentration trend charts.

[0054] For example, if the background concentration at point “1A01” is found to rise slowly but steadily from 0.1 mg / m³ to 0.8 mg / m³ over several months, although it is far from reaching the alarm threshold, this trend indicates that the pipe wall at that location may be slowly wearing away and thinning.

[0055] Based on this data trend, the maintenance department can proactively and systematically prioritize checking and addressing the pipeline during the next shutdown maintenance, achieving predictive maintenance, avoiding sudden leaks in the future, transforming unplanned shutdowns into planned shutdowns, and significantly improving the initiative and economy of equipment management.

[0056] This embodiment provides a coal pulverizer pulverized coal pipe leakage alarm system and method. It utilizes particulate matter sensors to perform real-time, uninterrupted automatic monitoring of the external environment of the pulverized coal pipe, enabling rapid signal detection in the early stages of pulverized coal leakage, completely solving the problem of lag associated with traditional manual inspections. Precise leak location greatly improves operation and maintenance efficiency. The unique sensor number accurately indicates the specific pipe section number or physical location of the leak. Operators or maintenance personnel can directly address the problem on-site, saving time spent searching through dense pipelines, resulting in an order-of-magnitude improvement in fault handling efficiency and a reduction in equipment downtime. The historical concentration data and alarm events recorded by the system can serve as important evidence for equipment condition assessment. Analysis of data trends can reveal the slow deterioration process before reaching the alarm threshold, thereby predicting the health status of the coal pulverizer pulverized coal pipe and scheduling maintenance in advance for preventative maintenance.

[0057] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A coal mill pulverized coal pipe leakage alarm system, characterized in that, include: Multiple particulate matter sensors are arranged on the outer wall of the coal powder tube of the coal mill to detect the particulate matter concentration in the area outside the coal powder tube in real time and generate corresponding concentration data. The control and processing unit is communicatively connected to the plurality of particulate matter sensors, and is used to receive and process the concentration data in real time, and compare the concentration data with an internally preset concentration threshold. When the concentration data reported by the particulate matter sensor continues to exceed the preset concentration threshold, an alarm trigger signal is generated. The audible and visual alarm module is communicatively connected to the control and processing unit and is used for audible alarms and visual indications.

2. The coal mill pulverized coal pipe leakage alarm system according to claim 1, characterized in that, The multiple particulate matter sensors are arranged linearly at intervals along the coal powder flow direction of a single coal powder pipe, and are located on the outer wall of the weak area of ​​the coal powder pipe where wear or weld cracking occurs.

3. The coal mill pulverized coal pipe leakage alarm system according to claim 1, characterized in that, When generating an alarm trigger signal, the control processing unit analyzes the identification information of the particulate matter sensor that triggered the alarm based on the mapping relationship between sensor identifiers and physical locations, and determines and outputs the number or location of the powder leakage area.

4. The coal mill pulverized coal pipe leakage alarm system according to claim 1, characterized in that, The control processing unit includes a CPU module and an I / O module that are interconnected; the I / O module is responsible for acquiring analog or digital signals from all particulate matter sensors, and the CPU module is responsible for performing data comparison, logical judgment, and issuing control commands.

5. The coal mill pulverized coal pipe leakage alarm system according to claim 3, characterized in that, The control processing unit further includes: receiving and storing the preset concentration threshold through a human-machine interface; periodically storing historical concentration data and alarm event records; and communicating with the upper-level monitoring system to upload alarm status and equipment information.

6. The coal mill pulverized coal pipe leakage alarm system according to claim 1, characterized in that, The sound and light alarm module includes a photon sign or a graphical human-machine interface, which is used to visually display the number or location description of the powder leakage area when the alarm is triggered.

7. The coal mill pulverized coal pipe leakage alarm system according to claim 6, characterized in that, The audible and visual alarm module is installed in the central control room or the area where the operation staff are stationed. Its audible alarm has different tones or voice prompts to distinguish the alarm level, and its light indicator is a flashing red light.

8. A method for alarming coal powder leakage in a coal mill's pulverized coal pipe, characterized in that, include: Using particulate matter sensors, real-time data on particulate matter concentration in the area is collected. Based on the particulate matter concentration data, a comparison and analysis are performed with a preset concentration threshold; when the concentration data is abnormal, the control processing unit generates an alarm trigger signal and locks the corresponding sensor number. Based on the alarm trigger signal, an audible and visual alarm is activated, and the specific powder leakage pipe section number is indicated.

9. The coal mill pulverized coal pipe leakage alarm method according to claim 8, characterized in that, The method of using a particulate matter sensor to collect particulate matter concentration data in the area in real time includes: Multiple monitoring points were arranged along the outer wall of the multiple pulverized coal pipes of the coal mill; The particulate matter concentration change around the pulverized coal pipe is monitored by a particulate matter sensor installed at the monitoring point. When the particulate matter concentration at a specific monitoring point exceeds a preset safety threshold, it is determined that a pulverized coal leakage has occurred in the pulverized coal pipeline section corresponding to that monitoring point, and an alarm signal containing location information is generated.

10. The coal mill pulverized coal pipe leakage alarm method according to claim 8, characterized in that, When the particulate matter concentration at a specific monitoring point exceeds a preset safety threshold, the process of determining that a pulverized coal leakage has occurred in the pulverized coal pipeline section corresponding to that monitoring point and generating an alarm signal containing location information includes: Start the image acquisition equipment located near the monitoring point to capture on-site images; The captured scene footage, along with the alarm signal and location information, will be sent to the monitoring center.

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