Soot blower operation state on-line monitoring system
By installing temperature sensors and data processing modules on the sootblower, the operating status of the boiler steam sootblower can be monitored and analyzed in real time, solving the problem of lack of online monitoring in the existing technology and improving the safety and stability of the boiler.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-17
- Publication Date
- 2026-03-27
AI Technical Summary
In the existing technology, boiler steam soot blowers lack effective online monitoring methods, which leads to failure to detect faults in a timely manner, making it difficult to predict boiler heating surface damage and potential equipment hazards. Relying on manual inspection is inefficient and unreliable.
Inner sleeve temperature sensors are installed at both ends of the lifting valve of each sootblower, and several outer sleeve temperature sensors are installed on the outer tube. The temperature data is monitored and analyzed in real time through the data processing module to identify the operating status of the sootblower, judge abnormal status and issue warnings, and provide fault prediction and maintenance prompts.
It enables online monitoring of boiler steam soot blowers, timely detection of abnormal conditions, reduction of the risk of boiler heating surface damage, improvement of equipment safety and stability, reduction of manual workload, and extension of equipment service life.
Smart Images
Figure CN121740280A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of boiler sootblower technology, and more specifically to an online monitoring system for the operating status of a sootblower. Background Technology
[0002] During boiler operation, ash and slag easily accumulate on the heating surfaces of water-cooled walls, superheaters, economizers, preheaters, and flues. Steam soot blowers utilize high-pressure boiler steam to purge these ash deposits, thus treating the flue gas and ash within the combustion chamber. Large thermal power plants typically have over a hundred steam soot blowers per boiler. However, with varying degrees of damage to the mechanical transmission mechanisms, motors, cables, and control components of most soot blowers, coupled with a lack of effective management, problems such as soot blower jamming and burnout, and damage to the heating surfaces, arise. Currently, the status of steam soot blowers is primarily monitored manually by operators. There are no online monitoring systems for any of the soot blowers; operators rely on on-site inspections to determine their operating status. This method is prone to failure in timely detection of soot blower malfunctions or leaks in the lifting valves, leading to excessive steam being blown into the furnace for extended periods and causing damage to the boiler's heating surfaces. Some factories monitor the stroke of the sootblower's blowing gun to determine if the sootblower is operating normally. However, there are no means to monitor internal leaks or blockages in the sootblower itself, making it impossible to detect potential equipment problems early. Real-time automatic online monitoring systems for steam sootblowers have not yet been developed or researched domestically or internationally. Summary of the Invention
[0003] To overcome the aforementioned deficiencies of the prior art, this invention provides an online monitoring system for the operating status of sootblowers. This system involves installing inner sleeve temperature sensors on the inner sleeves at both ends of the lifting valve of each sootblower, and several outer sleeve temperature sensors on the outer sleeve of each sootblower. This allows for real-time online monitoring of the temperatures in different areas of the inner and outer sleeves of the steam sootblower. After processing the collected data, the system extracts temperature data over a given period. By calculating and analyzing real-time temperature fluctuations, the system compares and analyzes the operating status of the sootblower, identifying and determining abnormal states including jamming, internal leakage, and limit switch malfunctions. It also identifies abnormal points and issues warnings. Finally, the system displays the sootblower status, fault predictions, and maintenance prompts in real time. This system effectively implements online monitoring of the boiler steam sootblower's operation, identifies and determines abnormal states and points, predicts in advance whether the sootblower equipment is operating normally, and provides timely alarms and reminders. This reduces the workload of operators, improves the safety and stability of the boiler unit, and solves the problems mentioned in the background art.
[0004] To achieve the above objectives, the present invention provides the following technical solution: An online monitoring system for the operating status of a sootblower includes: a temperature data acquisition module for real-time online monitoring of the temperature of the boiler steam sootblower; a data processing module for processing the acquired data and collecting, displaying, storing, and managing monitoring information from all temperature measuring points within the area; a feature extraction module for extracting and recording temperature data during the sootblower's idle and start-up states; a status identification and analysis module for identifying and calculating temperature changes in each area based on the sootblower's operating status and comparing and analyzing the sootblower's operating status; a judgment and early warning alarm module for judging and determining abnormal states, issuing early warning information, and implementing closed-loop control of the sootblower; and a visualization prompt module for displaying the sootblower's status, fault prediction, and maintenance prompts in real time.
[0005] Furthermore, the temperature data acquisition module includes an inner tube temperature sensor, an outer tube temperature sensor, and a data acquisition unit. There are two inner tube temperature sensors, and each of the two inner tube temperature sensors has a clamp on its inner side. The inner tube temperature sensor is fixedly connected inside the clamp, and the two clamps are respectively engaged and connected to the outer side of the inner tube at the front end and rear end of the sootblower lifting valve.
[0006] Furthermore, there are several outer tube temperature sensors, which are fixedly connected at equal intervals to the outer wall of the sootblower outer tube.
[0007] Furthermore, the data acquisition device is fixedly connected to the outside of the soot blower, and the data acquisition device is connected to the inner sleeve temperature sensor, the outer tube temperature sensor and the data processing module.
[0008] Furthermore, the temperature data extracted by the feature extraction module includes the range temperature over a duration and the temperature fluctuation within that range; in the idle state, no steam enters the lift valve and the steam outer pipe, and the temperature fluctuation is below 200°C; in the start-up state, steam enters the soot blowing outer pipe through the open lift valve, and the temperature fluctuation is between 200°C and 350°C.
[0009] Furthermore, the state recognition and analysis module identifies and calculates the sootblower's state, including: normal operation state, where the temperature fluctuation is between 200°C and 350°C over a duration period; overheating state, where the temperature threshold is above 350°C over a duration period; cooling state, where the temperature threshold is below 200°C over a duration period; equipment blockage state, where steam continuously enters the sootblower, causing the temperature to rise continuously, and the temperature threshold exceeds 350°C and tends to stabilize; and leakage state, where steam leaks from the sootblower and directly enters the flue, mixing with the flue airflow and causing the temperature of the outer tube of the sootblower to rise, while the temperature of the inner sleeve decreases due to steam leakage, and the temperature change is unstable over a duration period.
[0010] Furthermore, the judgment and early warning module judges and determines abnormal states, including jamming, internal leakage, and limit abnormality, by comparing the temperature data with the safety threshold based on the various data information.
[0011] Furthermore, the distance between the outer tube temperature sensor near the sootblower's outer tube release port and the release port is the radius of the release port.
[0012] Furthermore, the visualization prompt module displays in real time the temperature curves, over-temperature warnings, alarms, data records, and historical data of the sootblower outer tube and the lifting valve inner sleeve, identifying faults and abnormal areas and providing technical support for maintenance.
[0013] Compared with the prior art, the beneficial effects of the present invention are: This invention utilizes internal sleeve temperature sensors installed on the inner sleeves at both ends of the lifting valve of each sootblower, and several external sleeve temperature sensors installed on the outer sleeve of each sootblower, to monitor the temperature of different areas of the inner and outer sleeves of the steam sootblower in real time. A data processing module processes the collected data, a feature extraction module extracts the temperature range data over a given period, and temperature fluctuations are used to determine whether the sootblower is in an idle or running state. A status identification and analysis module calculates and analyzes the real-time temperature fluctuations to determine the sootblower's operating status. A judgment and early warning alarm module compares the temperature data with safety thresholds to determine and identify abnormal states, including jamming, internal leakage, and limit malfunctions, while simultaneously pinpointing the location of the abnormality and issuing warnings. Finally, a visualization module effectively displays the sootblower status, fault predictions, and maintenance prompts in real time. It can effectively implement online monitoring of the operation of boiler steam soot blowers, identify and determine abnormal states and abnormal points of steam soot blowers, predict in advance whether the working status of the soot blower equipment is normal, and provide timely alarm reminders, reduce the risk of boiler heating surface damage, reduce the workload of operators, improve the safety and stability of boiler units, and extend the service life of soot blowers. Attached Figure Description
[0014] To more clearly illustrate the technical solutions in the embodiments, the accompanying drawings will be briefly described below.
[0015] Figure 1 This is a schematic diagram of the system of the present invention; Figure 2 This is a schematic diagram of the system operation process of the present invention; Figure 3 This is a schematic diagram of the monitoring system of the present invention; Figure 4 This is a schematic diagram of the installation of the temperature data acquisition module in this invention; In the diagram: 1. Temperature data acquisition module; 11. Inner tube temperature sensor; 12. Outer tube temperature sensor; 13. Data acquisition unit; 14. Clamp; 2. Data processing module; 3. Feature extraction module; 4. Status recognition and analysis module; 5. Judgment and early warning alarm module; 6. Visual prompt module. Detailed Implementation
[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Specific mechanical structures of the present invention will be described in conjunction with the following references. Figures 1 to 4 The detailed description of the structure will be clearly presented. All structural details mentioned in the following embodiments are based on the accompanying drawings.
[0017] Please see Figures 1-4 In this embodiment of the invention, an online monitoring system for the operating status of a sootblower includes a temperature data acquisition module 1, which monitors the temperature of the boiler steam sootblower in real time; a data processing module 2, which processes the acquired data and completes the acquisition, display, storage, and management of monitoring information for all temperature measuring points within the area; a feature extraction module 3, which extracts and records temperature data for the sootblower's idle and start-up states; a status identification and analysis module 4, which identifies and calculates temperature changes in each area based on the sootblower's operating status and compares and analyzes the sootblower's operating status; a judgment and early warning alarm module 5, which judges and determines abnormal states, issues early warning information, and performs closed-loop control of the sootblower; and a visualization prompt module 6, which displays the sootblower's status, fault prediction, and maintenance prompts in real time.
[0018] Temperature data acquisition module 1 is connected to a designated location on the steam sootblower, enabling real-time online monitoring of the sootblower temperature. Module 1 consists of two inner tube temperature sensors 11, two outer tube temperature sensors 12, and a data acquisition unit 13. Each inner tube temperature sensor 11 has a clamp 14 on its inner side, with the sensor fixedly connected inside the clamp 14. The clamps 14 are respectively engaged and connected to the outer sides of the inner tubes at the front and rear ends of the sootblower's lifting valve, stably connecting the two sensors 11 to the valve. The clamps 14 secure the heat collector of the inner tube temperature sensor 11 to the inner tube of the sootblower's lifting valve, and the thermal resistor is installed on the heat collector, ensuring accurate measurement and secure installation without altering the original equipment structure. Depending on the difference in the installation margin between long-blown and short-blown heat exchangers, different types of thermal resistors are selected. For example, armored thermal resistors are used on long-blown heat exchangers; and end-face resistors are used on short-blown heat exchangers because the installation space is narrower, with the measuring end installed on the heat collection block.
[0019] Several external tube temperature sensors 12 are fixedly connected at equal intervals to the outer wall of the sootblower's outer tube. Mounting holes for each temperature sensor 12 are provided on the outer wall of the sootblower's outer tube, with the sensors completely inside these holes to ensure normal operation. The distance between the temperature sensor 12 near the sootblower's outer tube release port and the release port is the radius of the release port, effectively accommodating temperature monitoring in the release port area during short-duration sootblowing. A data acquisition unit 13 is fixedly connected to the outside of the sootblower. The data acquisition unit 13 connects to the inner tube temperature sensor 11, the outer tube temperature sensors 12, and the data processing module 2, transmitting the monitored temperature information to the data acquisition unit 13 in real time. The data processing module 2 is located outside the sootblower and processes the collected data, completing the acquisition, display, storage, and management of monitoring information for all temperature measurement points within the area.
[0020] Feature extraction module 3 is used to extract and record temperature data for both the idle and start-up states of the sootblower. The extracted temperature data includes the range temperature over a given period and the temperature fluctuation within that range. The real-time temperature of the outer tube and the inner sleeve of the sootblower's lifting valve is monitored by the outer tube temperature sensor 12 and the inner sleeve temperature sensor 11. When the temperature fluctuation is below 200℃, no steam enters the lifting valve or the outer tube, and the steam sootblower is in an idle state. When the steam sootblower is in the start-up state, steam enters the outer tube through the open lifting valve. Steam enters the two inner sleeves at both ends of the lifting valve and guides the steam into the outer tube. The temperature inside the inner sleeves and the outer tube gradually rises, and the temperature fluctuation stabilizes between 200℃ and 350℃, ensuring stable steam delivery.
[0021] The status identification and analysis module 4 identifies and calculates the temperature changes in various areas of the sootblower based on its operating status, in order to compare and analyze the sootblower's operating status. Specifically, a temperature fluctuation within the sootblower between 200℃ and 350℃ over a given period indicates normal operation; an overheated state indicates a temperature threshold above 350℃ over a given period; a cooling state indicates a temperature threshold below 200℃ over a given period; a blocked state indicates continuous steam entering the sootblower, causing the temperature to rise continuously, exceeding 350℃ and then stabilizing; and a leakage state indicates steam leaking from the sootblower and directly entering the flue, mixing with the flue airflow and causing the temperature of the outer tube of the sootblower to rise, while the temperature of the inner sleeve decreases due to steam leakage, resulting in unstable temperature changes over a given period.
[0022] The judgment and early warning module 5, based on various data information, compares the temperature data with the safety threshold to determine and identify abnormal states and locations, including jamming, internal leakage, and limit abnormalities. It then issues early warning information and implements closed-loop control of the sootblower, achieving self-diagnosis and self-healing of the sootblower. Jamming occurs when the sootblower's abnormal operating state alters the local heat distribution, leading to temperature changes and abnormally high local temperatures, resulting in local overheating. In this case, the sootblower's outer tube may not be able to exit the furnace properly. If the sootblower cannot exit in time after jamming, steam continues to scour the heated surface, causing an abnormal rise in tube wall temperature, resulting in local overheating or uneven heat absorption. This leads to abnormally high temperature fluctuations in the area where the outer tube temperature sensor 12 is located in the jammed area. During continuous blowing, multiple outer tube temperature sensors 12 distributed at different locations on the outer tube monitor temperature changes in different areas of the outer tube to pinpoint the jammed area where the sootblower has not exited in time.
[0023] Internal leakage occurs when there is a temperature difference in the inner sleeves at both ends of the lift valve. The temperature on the outside of the inner sleeve of the lift valve rises sharply. Internal leakage can cause steam to leak directly into the flue, resulting in an increase in the temperature of the metal wall around the leak point and the temperature of the flue gas, causing local or overall temperature abnormalities. At the same time, internal leakage can also cause the soot blower to jam.
[0024] Abnormal limit positioning caused the sootblower's outer tube to fail to extend or retract fully according to the predetermined stroke, resulting in a deviation of the sweeping range from the designed position. Specifically, the abnormal limit positioning caused the sootblower to extend excessively into the furnace water-cooled wall area, resulting in localized over-blowing. This led to an abnormal increase in heat absorption by the water-cooled wall, causing a drop in steam temperature, and a downward trend in the temperature fluctuations collected by the outer tube temperature sensor 12. Conversely, the sootblower's incomplete extension resulted in incomplete cleaning of the heated surface, leading to uneven heat absorption in localized areas. This caused a greater deviation in steam temperature and a decrease in heat transfer efficiency, resulting in an upward trend in the temperature fluctuations collected by the outer tube temperature sensor 12.
[0025] The visualization prompt module 6 can be equipped with a display screen. The visualization prompt module 6 displays the temperature curves, over-temperature warnings, alarms, data records and historical data of the sootblower outer tube and the inner sleeve of the lifting valve in real time, so as to identify faults and abnormal areas and provide technical support for maintenance.
[0026] Inner sleeve temperature sensors 11 are installed on the inner sleeves at both ends of the lifting valve of each sootblower, and several outer sleeve temperature sensors 12 are installed on the outer sleeve of each sootblower to monitor the temperature of different areas of the inner and outer sleeves of the steam sootblower in real time. The communication card of the DCS control system is used to realize the data acquisition of sootblower temperature through DCS communication configuration. The data processing module 2 processes the acquired data information to complete the acquisition, display, storage and management of monitoring information of all temperature measuring points in the area. The feature extraction module 3 extracts the range temperature data within a certain period of time, judges and analyzes the sootblower's idle state and start-up state based on temperature fluctuations. The status identification and analysis module 4 calculates and analyzes the real-time temperature fluctuations to compare and analyze the sootblower's operating status. The judgment and early warning alarm module 5 judges and determines abnormal states, including jamming, internal leakage and limit abnormality, based on the data information and compares the temperature data with the safety threshold. At the same time, it determines the abnormal point and issues a warning. Finally, the visualization prompt module 6 displays the sootblower status, fault prediction and maintenance prompts in real time. It can effectively implement online monitoring of the operation of boiler steam soot blowers, identify and determine abnormal states and abnormal points of steam soot blowers, predict in advance whether the working status of the soot blower equipment is normal, and provide timely alarm reminders, thereby reducing the risk of boiler heating surface damage, reducing the workload of operators, improving the safety and stability of boiler units, and extending the service life of soot blowers.
[0027] The working principle of this invention is as follows: Inner sleeve temperature sensors 11 are installed on the inner sleeves at both ends of the sootblower lifting valve, and several outer sleeve temperature sensors 12 are installed on the outer sleeve of the sootblower. These sensors monitor the temperature of different areas of the inner and outer sleeves of the steam sootblower in real time. Data acquisition unit 13 collects data and transmits it to data processing module 2 for information processing. This completes the collection, display, storage, and management of monitoring information for all temperature measurement points within the area. Feature extraction module 3 extracts the range temperature data within a given time period. Status recognition and analysis module 4 calculates and analyzes the real-time temperature fluctuations to determine the sootblower's operating status. Judgment and early warning alarm module 5 judges and determines abnormal states, including jamming, internal leakage, and limit abnormalities, based on the data and the safety threshold of the temperature data. It also identifies the abnormal points and issues warnings. Finally, visualization prompt module 6 displays the sootblower status, fault prediction, and maintenance prompts in real time, predicting whether the sootblower equipment is operating normally and providing timely alarm reminders.
[0028] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.
Claims
1. An online monitoring system for the operating status of a sootblower, characterized in that, Includes a temperature data acquisition module (1), which monitors the temperature of the boiler steam soot blower in real time; Data processing module (2) processes the collected data information and completes the collection, display, storage and management of monitoring information of all temperature measuring points in the area; Feature extraction module (3) extracts and records temperature data of the sootblower in idle and start-up states; The status identification and analysis module (4) identifies and analyzes the temperature changes in each area based on the working status identification of the sootblower, and compares and analyzes the operating status of the sootblower. Judgment and early warning alarm module (5), the judgment and early warning alarm module (5) judges and determines the abnormal state, issues early warning information and controls the soot blower in a closed loop; The visualization prompt module (6) displays the status of the sootblower, fault prediction and maintenance prompts in real time.
2. The online monitoring system for the operating status of a sootblower according to claim 1, characterized in that, The temperature data acquisition module (1) includes an inner tube temperature sensor (11), an outer tube temperature sensor (12), and a data acquisition unit (13). There are two inner tube temperature sensors (11). Each inner tube temperature sensor (11) is provided with a clamp (14) on its inner side. The inner tube temperature sensor (11) is fixedly connected inside the clamp (14). The two clamps (14) are respectively engaged and connected to the outer side of the inner tube at the front end and rear end of the soot blower lifting valve.
3. The online monitoring system for the operating status of a sootblower according to claim 2, characterized in that, The number of the outer tube temperature sensors (12) is several, and the several outer tube temperature sensors (12) are fixedly connected at equal intervals to the outer wall of the sootblower outer tube.
4. The online monitoring system for the operating status of a sootblower according to claim 2, characterized in that, The data acquisition unit (13) is fixedly connected to the outside of the soot blower. The data acquisition unit (13) is connected to the inner sleeve temperature sensor (11), the outer tube temperature sensor (12) and the data processing module (2).
5. The online monitoring system for the operating status of a sootblower according to claim 1, characterized in that, The temperature data extracted by the feature extraction module (3) includes the range temperature within the duration and the temperature fluctuation within the range; in the idle state, no steam enters the lifting valve and the steam outer pipe, and the temperature fluctuation is below 200℃; in the start-up state, steam enters the soot blowing outer pipe through the open lifting valve, and the temperature fluctuation is between 200℃ and 350℃.
6. The online monitoring system for the operating status of a sootblower according to claim 1, characterized in that, The state identification and analysis module (4) identifies and calculates the sootblower state, including normal operation state, where the temperature fluctuation is between 200°C and 350°C within the duration range; overheating state, where the temperature threshold is higher than 350°C within the duration range; cooling state, where the temperature threshold is lower than 200°C within the duration range; equipment blockage state, where steam continuously enters the sootblower, causing the temperature to rise continuously, and the temperature threshold exceeds 350°C and tends to stabilize; and leakage state, where steam leaks from the sootblower and directly enters the flue, and the mixed flue airflow causes the temperature of the outer tube of the sootblower to rise, while the temperature of the inner sleeve decreases due to steam leakage, and the temperature change is unstable within the duration range.
7. The online monitoring system for the operating status of a sootblower according to claim 1, characterized in that, The judgment and early warning module (5) judges and determines abnormal states, including jamming, internal leakage and limit abnormality, by comparing the safety threshold of the temperature data according to the data information.
8. The online monitoring system for the operating status of a sootblower according to claim 2, characterized in that, The distance between the outer tube temperature sensor (12) near the sootblower outer tube release port and the release port is the radius of the release port.
9. The online monitoring system for the operating status of a sootblower according to claim 1, characterized in that, The visualization prompt module (6) displays in real time the temperature curves, over-temperature warnings, alarms, data records and historical data of the outer tube of the sootblower and the inner sleeve of the lifting valve, and identifies faults and abnormal areas, providing technical support for maintenance.