System and method for detecting water channeling of blast furnace compressed air distribution bag

Abstract

The invention belongs to the technical field of air distribution bags, and particularly discloses a system for detecting water channeling of a blast furnace compressed air air distribution bag, which comprises an air distribution bag, a plurality of air branch pipes communicated with the air distribution bag, an electromagnetic valve arranged on each air branch pipe, a thermodetector arranged on each air branch pipe and an acoustic sensor arranged on each air branch pipe. Each acoustic sensor is connected in parallel with an oscilloscope and a PLC (Programmable Logic Controller), and the thermodetector and the electromagnetic valve are electrically connected with the PLC; when water flows into the compressed air branch pipe, the temperature and the sound in the compressed air branch pipe change, the temperature and the sound in the compressed air branch pipe are detected through the PLC to judge whether the water flows or not, the electromagnetic valve of the compressed air branch pipe is closed in time, and water is prevented from entering downstream equipment; an operator verifies whether the thermodetector fails or not according to whether sound waves in the oscilloscope are stable or not; the problems that early warning cannot be conducted on the situation that industrial water reversely flows into a compressed air distribution bag in time, and consequently equipment damage and system faults are caused are solved.

Description

Technical Field

[0001] This invention relates to the field of gas distribution manifold technology, and specifically to a system and method for detecting water leakage in the compressed air distribution manifold of a blast furnace. Background Technology

[0002] The blast furnace tapping platform is the core operating area of ​​the blast furnace ironmaking system. Located in front of the blast furnace hearth, it is a large, open working platform with special reinforcement. Its main function is to safely collect, guide, and transport the high-temperature molten iron and slag discharged from the blast furnace taphole. The platform is typically equipped with key equipment such as main iron channels, branch iron channels, slag spreaders, oscillating nozzles, or molten iron ladles to separate the molten iron from the slag and inject it into transport cars. The compressed air distribution manifold on the blast furnace tapping platform is a crucial air source treatment and distribution device. It is usually a pressurized tank installed on the tapping platform, outputting about a dozen branch compressed air pipes. These pipes are mainly used for atomized water injection for the furnace opening machine, atomized water cooling for the furnace front mud gun, atomized water dust suppression for the hot blast stove gravity dust collector, atomized water dust suppression for the hot blast stove dry bag filter, blowing and cooling for the tuyere platform area air supply device, and blowing and cleaning the bag filters at the taphole.

[0003] The supply pressure of compressed air is generally around 0.65 MPa, while the pressure of industrial water used in conjunction with atomization is generally around 1.60 MPa. The temperature of high-pressure industrial water is generally controlled at around 32±2℃, while the temperature of compressed air after being cooled by a cooler is generally 25±3℃. If the one-way check valve in the compressed air pipeline of the furnace opening machine, mud gun blowing atomized water, gravity dust removal atomized water dust suppression of hot blast stove, and dry bag dust removal atomized water dust suppression of hot blast stove malfunctions, it will cause industrial water to backflow into the compressed air pipeline, and then into the compressed air distribution manifold. The impact of high-speed water flow will damage pneumatic components, such as cylinders and valves, causing precision tools to malfunction or rust and jam. Water sprayed into high-temperature areas with compressed air may cause steam explosions or splashes. Water freezing in the pipeline will cause blockages, and mixing with oil will form emulsions that aggravate corrosion and wear. Summary of the Invention

[0004] The purpose of this invention is to provide a system and method for detecting water leakage in the compressed air distribution manifold of a blast furnace, so as to solve the problem of failure to provide timely warning of industrial water backflow into the compressed air distribution manifold, which leads to equipment damage and system failure.

[0005] To achieve the above objectives, the basic solution provided by this invention is as follows: a system for detecting water leakage in the compressed air distribution manifold of a blast furnace, comprising a distribution manifold, several air branch pipes connected to the distribution manifold, each air branch pipe being equipped with a solenoid valve, a thermometer (a platinum resistance temperature sensor) on each air branch pipe, an acoustic sensor (a piezoelectric ceramic acoustic emission sensor) on each air branch pipe, and an oscilloscope and a PLC controller connected in parallel on each acoustic sensor. The thermometer and the solenoid valve are both electrically connected to the PLC controller.

[0006] The principle and beneficial effects of this invention are as follows: Since the cooled compressed air is 25±3℃ and the industrial water temperature is 32±2℃, when industrial water enters the branch pipe of the compressed air distributor, the temperature inside the compressed air branch pipe changes. The temperature sensor detects this temperature change and transmits it to the PLC controller. The PLC controller then further determines whether water leakage has occurred by observing changes in the sound waves inside the compressed air branch pipe. After water leakage, water droplets or streams violently impact the pipe wall, collide with each other, or form turbulence in the high-pressure airflow, causing abrupt changes in the time and frequency domains of the sound waves. The PLC controller then determines water leakage based on these changes, issues an early warning, and simultaneously controls the solenoid valve to close. After closure, the operator handles the faulty compressed air branch pipe experiencing water leakage. When water leakage occurs in the compressed air branch pipe, the temperature and sound inside the branch pipe change. The PLC controller detects the temperature and sound inside the compressed air branch pipe to determine if water leakage has occurred and promptly closes the solenoid valve of the compressed air branch pipe, cutting off the airflow inside the branch pipe, preventing moisture from entering downstream equipment, and reducing equipment damage.

[0007] Option 2, which is the basic solution of this invention: a method for detecting water leakage in the compressed air distribution manifold of a blast furnace, comprising the following steps: S1. The thermometer detects the temperature inside the air branch pipe in real time and transmits the temperature to the PLC controller. The acoustic sensor detects the sound inside the air branch pipe in real time and converts the sound into an electrical signal, which is then transmitted to the PLC controller and oscilloscope. Temperature threshold and sound threshold are set on the human-machine interface of the PLC controller. The S2.PLC controller compares the actual temperature inside the air branch pipe with the temperature threshold, and determines whether to perform a re-inspection based on the change in the actual temperature. S3. During the re-inspection, the PLC controller compares the actual sound from the acoustic sensor with the sound threshold to determine whether to issue an alarm, and at the same time controls the solenoid valve to switch on and off.

[0008] Before use, set the temperature and sound thresholds on the PLC controller's human-machine interface. The PLC controller receives real-time temperature readings from the thermometer and real-time sound readings from the acoustic sensor, converting them into electrical signals. The PLC controller first compares the actual temperature in the air branch pipe with the temperature threshold to determine if water is leaking into the air branch pipe. Then, it verifies the leak by checking the sound changes in the air branch pipe. Once water leakage is confirmed, it controls the solenoid valve to close. Temperature changes serve as a sensitive preliminary indication of water leakage, while abnormal pulse changes in sound provide independent acoustic verification. The combination of these two factors effectively avoids false alarms from a single sensor. After confirmation by both signals, the PLC controller automatically triggers the solenoid valve to close, significantly shortening the response time from water leakage to cutting off the gas supply. This reduces reliance on manual intervention and ensures stable and reliable automatic protection even in the complex and harsh environment of the blast furnace tapping area.

[0009] Option 3, which is the preferred option of Option 2, has a temperature threshold of 20-30℃ and a sound threshold of 85-115dB in step S1.

[0010] Option 4, which is the preferred option of Option 2, involves the following steps: In step S2, if the PLC controller detects that 20℃ < actual temperature < 30℃, the PLC controller continues to monitor the temperature inside the air branch pipe. If the PLC controller detects that the actual temperature is ≤ 20℃ or 30℃ ≤ actual temperature, the PLC controller performs a re-check based on the sound changes detected by the acoustic sensor. When a small amount of water enters the air branch pipe, the liquid water rapidly atomizes and evaporates in the compressed air. This process absorbs a large amount of latent heat of vaporization, carrying away heat from the surrounding air and pipe walls. When a large amount of water enters the air branch pipe, the temperature of the industrial water is higher than the temperature of the compressed air, causing the temperature inside the air branch pipe to rise. This temperature change is a characteristic for judging water ingress.

[0011] Option 5, which is a preferred option of Option 2, involves step S3. If the PLC controller detects that the actual sound level is between 85-95dB, it issues a warning. The operator then checks the temperature measuring instrument based on the sound waves detected by the oscilloscope. If the PLC controller detects that the actual sound level is between 95-115dB, it closes the solenoid valve and issues a warning about water leakage in the air branch pipe. When water enters the air branch pipe, water droplets collide with the pipe wall, collide with each other, or form turbulence under high-pressure airflow, generating abnormal sound waves. The PLC analyzes the electrical signals transmitted by the acoustic sensor and compares them with preset sound characteristic thresholds to verify whether water leakage has occurred.

[0012] Option 6, which is the preferred option of option 5, requires the operator to inspect the temperature measuring instrument if the waveform of the sound wave in the oscilloscope is stable. If irregular pulses appear in the waveform of the sound wave in the oscilloscope, the operator does not need to inspect the temperature measuring instrument and should promptly close the solenoid valve. The oscilloscope is then used to verify again whether there is water leakage in the air branch pipe, thereby increasing the accuracy and reliability of the overall system decision. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of a system for detecting water leakage in the compressed air distribution manifold of a blast furnace according to the present invention. Detailed Implementation

[0014] The present invention will be further described in detail below through specific embodiments: The reference numerals in the accompanying drawings include: 1. air distribution manifold, 2. air branch pipe, 3. thermometer, 4. acoustic sensor, and 5. solenoid valve.

[0015] Example 1 like Figure 1 As shown: A system for detecting water leakage in the compressed air distribution manifold of a blast furnace includes a distribution manifold 1, which is connected to several air branch pipes 2. Each air branch pipe 2 is equipped with a solenoid valve 5 and a thermometer 3, which is a platinum resistance temperature sensor, model Pt100. Each air branch pipe 2 is also equipped with an acoustic sensor 4, which is a piezoelectric ceramic acoustic emission sensor, model GT200B. Each acoustic sensor 4 is connected in parallel with an oscilloscope and a PLC controller. The thermometer 3 and the solenoid valves 5 are both electrically connected to the PLC controller.

[0016] The implementation method of this embodiment is as follows: When industrial water enters the branch pipe of the compressed air distributor 1, the temperature inside the compressed air branch pipe 2 changes. The thermometer 3 detects the temperature change and transmits it to the PLC controller. The PLC controller determines whether water is leaking into the compressed air branch pipe 2 based on the temperature change. Then, the acoustic sensor 4 detects the sound change inside the compressed air branch pipe 2. The PLC controller then verifies whether water is leaking into the compressed air branch pipe 2 based on the sound change. When water leaks into the air branch pipe 2, the PLC controller issues an early warning and simultaneously controls the solenoid valve 5 to close, cutting off the airflow in the air branch pipe 2, preventing water from entering downstream equipment and reducing equipment damage.

[0017] Example 2 A method for detecting water leakage in the compressed air distribution manifold of a blast furnace includes the following steps: S1. The thermometer 3 detects the temperature inside the air branch pipe 2 in real time and transmits the temperature to the PLC controller. The acoustic sensor 4 detects the sound inside the air branch pipe 2 in real time and converts the sound into an electrical signal and transmits it to the PLC controller and oscilloscope. The temperature threshold and sound threshold are set on the human-machine interface of the PLC controller. The temperature threshold is 20-30℃ and the sound threshold is 85-115dB. S2. The PLC controller compares the actual temperature inside the air branch pipe 2 with the temperature threshold. If the PLC controller detects that 20℃ < actual temperature < 30℃, the PLC controller continues to detect the temperature inside the air branch pipe 2. If the PLC controller detects that the actual temperature ≤ 20℃ or 30℃ ≤ actual temperature, the PLC controller performs a re-check based on the sound change detected by the acoustic sensor 4. S3. During the retest, the PLC controller compares the actual sound from the acoustic sensor 4 with the sound threshold to determine whether to issue a warning. If the PLC controller detects that the actual sound is within the range of 85-95dB, it issues a warning. The operator verifies whether the temperature measuring instrument 3 is faulty based on the sound wave from the oscilloscope. If the waveform of the sound wave in the oscilloscope is stable, the operator needs to repair the temperature measuring instrument 3. If the waveform of the sound wave in the oscilloscope shows irregular pulses, the operator does not need to repair the temperature measuring instrument 3. If the PLC controller detects that the actual sound is within the range of 95-115dB, it controls the solenoid valve 5 to close and issues a warning.

[0018] The implementation method of this embodiment is as follows: Before use, the temperature threshold and sound threshold are set on the human-machine interface of the PLC controller. The PLC controller receives the temperature inside the air branch pipe 2 detected in real time by the thermometer 3, and the sound inside the air branch pipe 2 detected in real time by the acoustic sensor 4 and converts it into an electrical signal. When the PLC controller detects that the actual temperature is 18℃, the PLC controller will re-check according to the sound change detected by the acoustic sensor 4. During the re-check, when the PLC controller detects that the actual sound is 89dB, the PLC controller will issue an early warning. If the waveform of the sound wave in the oscilloscope is stable, it means that the thermometer 3 has made a detection error. The operator needs to repair the thermometer 3. At the same time, it means that there is no water leakage in the air branch pipe 2. Cut off the airflow in the air branch pipe 2 to prevent water from entering the downstream equipment. The operator will handle the fault in the air branch pipe 2 where water leakage occurs. When the PLC controller detects that the actual temperature is 18℃, the PLC controller will re-check based on the change in sound detected by the acoustic sensor 4. During the re-check, if the PLC controller detects that the actual sound is 89dB, the PLC controller will issue an early warning. If irregular pulses appear in the waveform of the sound wave in the oscilloscope, the operator does not need to repair the temperature measuring instrument 3 and should promptly control the solenoid valve 5 to close. This also indicates that water leakage has occurred in the air branch pipe 2. When the PLC controller detects that the actual temperature is 26℃, the PLC controller will re-check based on the change in sound detected by the acoustic sensor 4. During the re-check, if the PLC controller detects that the actual sound is 89dB, the PLC controller will not issue a warning. If the operator observes that the waveform of the sound wave in the oscilloscope is stable, it indicates that there is no water leakage in the air branch pipe 2. When the PLC controller detects that the actual temperature is 35℃, the PLC controller will recheck based on the change in sound detected by the acoustic sensor 4. During the recheck, if the PLC controller detects that the actual sound is 98dB, the PLC controller will issue an early warning of water leakage in the air branch pipe 2 and control the solenoid valve 5 to close, cutting off the airflow in the air branch pipe 2 to prevent moisture from entering the downstream equipment. The operator will then handle the fault in the air branch pipe 2 where water has leaked.

[0019] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific structures and characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A system for detecting water leakage in the compressed air distribution drum of a blast furnace, characterized in that, It includes an air distribution manifold (1), which is connected to several air branch pipes (2). Each air branch pipe (2) is equipped with a solenoid valve (5), a thermometer (3), and an acoustic sensor (4). Each acoustic sensor (4) is connected in parallel with an oscilloscope and a PLC controller. The thermometer (3) and the solenoid valve (5) are both electrically connected to the PLC controller.

2. A method for detecting water leakage in the compressed air distribution manifold of a blast furnace, characterized in that, Includes the following steps: S1. The thermometer (3) detects the temperature inside the air branch pipe (2) in real time and transmits the temperature to the PLC controller. The acoustic sensor (4) detects the sound inside the air branch pipe (2) in real time and converts the sound into an electrical signal and transmits it to the PLC controller and oscilloscope. The temperature threshold and sound threshold are set on the human-machine interface of the PLC controller. S2. The PLC controller compares the actual temperature inside the air branch pipe (2) with the temperature threshold, and determines whether to re-inspect based on the change in the actual temperature. S3. During the re-inspection, the PLC controller compares the actual sound of the acoustic sensor (4) with the sound threshold to determine whether to issue an alarm, and at the same time controls the solenoid valve (5) to switch on and off.

3. The method for detecting water leakage in the compressed air distribution drum of a blast furnace according to claim 2, characterized in that, In step S1, the temperature threshold is 20-30℃ and the sound threshold is 85-115dB.

4. The method for detecting water leakage in the compressed air distribution drum of a blast furnace according to claim 2, characterized in that, In step S2, if the PLC controller detects that 20℃ < actual temperature < 30℃, the PLC controller continues to detect the temperature inside the air branch pipe (2). If the PLC controller detects that the actual temperature is ≤ 20℃ or 30℃ ≤ actual temperature, the PLC controller performs a re-inspection based on the change in electrical signal inside the air branch pipe (2) detected by the acoustic sensor (4).

5. The method for detecting water leakage in the compressed air distribution drum of a blast furnace according to claim 2, characterized in that, In step S3, if the PLC controller detects that the actual sound range is 85-95dB, the PLC controller will issue an early warning. The operator will check the temperature measuring instrument (3) according to the sound wave of the oscilloscope. If the PLC controller detects that the actual sound range is 95-115dB, the PLC controller will control the solenoid valve (5) to close and issue an early warning of water leakage in the air branch pipe (2).

6. The method for detecting water leakage in the compressed air distribution drum of a blast furnace according to claim 5, characterized in that, If the waveform of the sound wave in the oscilloscope is stable, the operator needs to inspect the temperature measuring instrument (3). If the waveform of the sound wave in the oscilloscope shows irregular pulses, the operator does not need to inspect the temperature measuring instrument (3) and should promptly close the solenoid valve (5).

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