A coal-fired sootblower leak adaptive monitoring method

Abstract

The application discloses a kind of coal-fired soot blower leakage self-adaptive monitoring method, it is related to soot blower technical field, rely on matching monitoring device, adopt sealed cavity air pressure, pipeline ultrasonic, air pressure displacement linkage triple self-adaptive monitoring logic, complete installation and debugging, operation monitoring, leakage early warning, fault reset whole process operation.Monitoring device adopts clamping cover buckling structure and is fixed in pipeline flange, air bag ring self-adaptive sealing, adaptation 0.8-1.5MPa steam pressure and 300-800 DEG C furnace temperature working condition.Through three data cross verification, can accurately identify microleakage and severe leakage, realize grading early warning and leakage point positioning, positioning error ≤5cm.Method has working condition, precision, early warning triple self-adaptive, forms monitoring early warning reset automatic closed loop, without manual intervention.Installation is simple, without modifying pipeline, monitoring element integration protection, operation and maintenance cost is low, fault rate is low, can effectively capture microleakage, prevent fault expansion, meet coal-fired power plant intelligent, fine operation and maintenance requirements.

Description

Technical Field

[0001] This invention relates to the field of sootblower technology, specifically to an adaptive monitoring method for leakage in coal-fired sootblowers. Background Technology

[0002] In the operation of coal-fired power plant boilers, soot blowers are core auxiliary equipment for maintaining furnace heat exchange efficiency and removing ash from heated surfaces. Among them, steam soot blowers are widely used in various coal-fired boiler systems due to their good cleaning effect and strong adaptability. Currently, the industry's monitoring methods for leaks in coal-fired soot blower pipelines mainly rely on manual inspection, conventional pressure sensor monitoring, and single-point ultrasonic monitoring. This monitoring method, which combines basic sensing equipment with manual inspection, has become the standard technical solution for the operation and maintenance of soot blower systems in coal-fired power plants. To a certain extent, it can identify obvious pipeline leaks and meet basic operation and maintenance monitoring needs.

[0003] Existing sootblower leakage monitoring technologies suffer from limitations in their simplistic and passive approach, making accurate leak identification and early warning difficult. Manual inspections are constrained by inspection cycles and on-site conditions. The environment surrounding coal-fired boiler furnaces is harsh, characterized by high temperatures, high dust levels, and strong vibrations, making 24 / 7 inspections impossible. This easily leads to overlooking minor leaks in the pipeline, which can gradually develop into major leaks over time, resulting in significant steam waste and reduced furnace thermal efficiency. Conventional pressure sensors and single-point ultrasonic monitoring can only monitor a single location and parameter within the pipeline, failing to adapt to the drastic fluctuations in steam pressure and temperature during sootblower start-up and shutdown. This data distortion due to changing conditions can lead to misjudgments or missed detections, making it difficult to capture the parameter changes characteristic of minor leaks.

[0004] Existing monitoring technologies suffer from a lack of coordinated early warning mechanisms, a disconnect between monitoring and protection, and poor equipment sealing adaptability, further reducing the reliability of leak monitoring. On one hand, traditional monitoring equipment can only collect data without a corresponding automatic early warning and coordinated control structure. Even if a leak signal is detected, manual confirmation and activation of protective measures are required, resulting in a significant response delay that can easily lead to further expansion of the leak and even secondary failures such as steam splashing and equipment corrosion. On the other hand, the sealing structure at the connection between traditional monitoring devices and sootblower pipes is simple and lacks adaptive sealing adjustment capabilities. Under the influence of pipe thermal expansion and contraction and on-site vibration, gaps can easily appear at the sealing points, affecting not only the accuracy of monitoring data but also potentially allowing external dust and moisture to enter the monitoring area, damaging monitoring components and increasing equipment maintenance costs and failure rates.

[0005] In summary, existing leakage monitoring technologies for coal-fired soot blowers can no longer meet the needs of power plants for refined and intelligent operation and maintenance. There is an urgent need for a leakage monitoring method and device that can adapt to complex operating conditions, achieve multiple monitoring, and provide automatic linkage early warning, in order to solve many of the shortcomings of existing technologies. Summary of the Invention

[0006] 1. The technical problem to be solved by the present invention

[0007] The purpose of this invention is to propose an adaptive monitoring method for leakage in coal-fired soot blowers to solve the following problems existing in the prior art: (1) Solve the technical problems of existing monitoring methods being single and passive, and prone to missed or misjudged cases; Existing leak monitoring for coal-fired sootblowers relies on manual inspections and single pressure / ultrasonic monitoring. Due to limitations in inspection cycles and harsh operating conditions, 24-hour monitoring cannot be achieved, and micro-leakage issues are easily missed. Furthermore, single-parameter monitoring cannot adapt to the drastic fluctuations in steam pressure and temperature during sootblower start-up and shutdown, which can easily lead to data distortion and make it difficult to capture parameter change characteristics during micro-leakage stages, resulting in insufficient ability to accurately identify and provide early warning of leaks.

[0008] (2) Solve the technical problems of disconnect between monitoring and early warning protection, and poor equipment sealing compatibility; Traditional monitoring equipment can only collect data and lacks a supporting automatic early warning and linkage control structure. After a leak is detected, manual confirmation and activation of protection are required. The delayed response can easily lead to the expansion of the leak and secondary failures. At the same time, the sealing structure between the monitoring device and the pipeline is simple and lacks self-adjustment capability. Under the influence of pipeline thermal expansion and contraction and strong vibrations at the site, sealing gaps are easily formed, which not only affects the accuracy of monitoring data, but also makes the monitoring elements susceptible to damage from dust and moisture intrusion, increasing operation and maintenance costs and equipment failure rate.

[0009] 2. Technical Solution To achieve the above objectives, the present invention provides the following technical solution: an adaptive monitoring method for leakage in a coal-fired sootblower, implemented based on an adaptive monitoring device for leakage in a coal-fired sootblower. This method achieves accurate leakage identification and early warning through a triple adaptive monitoring logic combining sealed cavity air pressure monitoring, pipeline ultrasonic monitoring, and air pressure-displacement linkage monitoring. The method comprises four stages: device installation and commissioning, normal operation monitoring, leakage identification and early warning, and fault reset and recovery. The specific steps are as follows: S1. Device Installation and Debugging: Fasten the first and second clips onto the flange of the pipe to be monitored by the soot blower and tighten them so that the sealing sleeve fits against the outer wall of the pipe to form a sealed monitoring cavity; start the air pump to inflate the airbag ring to enhance the sealing performance of the sealed monitoring cavity; calibrate the ultrasonic monitoring reference values ​​of the first and second monitors, adjust the displacement monitoring accuracy of the measuring board for the piston resistance rod and set the displacement zero point, and turn on the control panel to confirm that the monitoring data can be transmitted normally to the terminal industrial control computer; S2. Normal Operation Monitoring: After the soot blower is started, the device enters the normal monitoring mode. The sealed monitoring chamber maintains stable air pressure. The first and second monitoring instruments collect ultrasonic propagation parameters inside the pipeline in real time and adaptively adjust the ultrasonic monitoring parameter thresholds according to changes in steam pressure and temperature. The air pressure sealing plug inside the air pressure cylinder remains stationary and the piston resistance rod has no displacement. The terminal industrial control computer performs fusion analysis on the air pressure, ultrasonic, and displacement data. When a single data fluctuation occurs, the sampling frequency of the other two monitoring devices is automatically increased. S3. Leakage Identification and Early Warning: When a pipeline leaks, high-pressure steam seeps into the sealed monitoring chamber, causing a change in the internal pressure. This pushes the pressure sealing plug to move, causing the connecting plate, detection and stabilizing block, and piston resistance rod to move synchronously. The measuring plate captures the displacement of the piston resistance rod, while the first and second monitors capture changes in ultrasonic propagation parameters. The terminal industrial control computer determines the leakage level and triggers a graded early warning through cross-validation of the three data sets. Simultaneously, it determines the leak location based on the difference in parameter changes between the two ultrasonic monitors and the direction of piston resistance rod displacement, with an error range ≤5cm. Among these, a leakage rate <0.05MPa / min is considered a micro-leak, triggering a Level 1 early warning; a leakage rate ≥0.05MPa / min is considered a severe leak, triggering a Level 2 early warning and potentially sending a shutdown suggestion to the sootblower control system. S4. Fault Reset and Recovery: After the maintenance personnel complete the repair of the leak point, they operate the control panel to release the residual air pressure in the sealing monitoring chamber, so that the air pressure sealing plug and piston resistance rod return to their initial positions and the displacement reference value is recalibrated; the air pump is restarted to inflate the airbag ring to restore the sealing performance, each monitor is restarted and new reference values ​​are collected, and after confirming that the data is normal, the device re-enters the normal operation monitoring mode.

[0010] Preferably, the first and second clips are fastened with bolts, and the sealing sleeves are sealed together by a sealing gasket on their surface. After inflation, it must be confirmed that there is no air pressure leakage between the airbag ring and the sealing sleeve.

[0011] Preferably, the ultrasonic monitoring parameters include ultrasonic propagation speed and amplitude, and the device is adapted to the operating conditions of steam pressure fluctuation of 0.8-1.5MPa and furnace temperature fluctuation of 300-800℃ during the start-up and shutdown of the sootblower.

[0012] Preferably, in the case of a minor leak, the displacement of the piston resistor rod is 0.5-2mm, and the first-level warning is a green audible and visual alarm. The transmission module sends the leak location and initial data to the auxiliary control room. In the case of a severe leak, the displacement of the piston resistor rod exceeds 2mm, and the second-level warning is a red audible and visual alarm. The transmission module continuously uploads the leak level and real-time data.

[0013] Preferably, the adaptive capability of the method is reflected in: adapting to the working condition based on the real-time changes in steam pressure and temperature in the sootblower pipeline; automatically increasing the sampling frequency of the other two monitoring devices when a single monitoring data fluctuates to achieve adaptive monitoring accuracy; and automatically triggering different levels of early warning based on the amount of leakage to achieve adaptive early warning level.

[0014] Preferably, the adaptive monitoring device for leakage of a coal-fired soot blower includes a first cover, a second cover installed on one side of the first cover, a control panel installed on the side of the first cover away from the second cover, and sealing sleeves installed on the first cover and the second cover respectively. The adaptive monitoring device for leakage of a coal-fired soot blower also includes a sealing air pressure monitoring mechanism and a linkage control early warning and protection mechanism. The sealing pressure monitoring mechanism is installed in the sealing sleeve and is used for multiple protection monitoring when the pipeline leaks. The linkage control early warning and protection mechanism is installed in the first cover, and the linkage control early warning and protection mechanism is used for automated early warning.

[0015] Preferably, the sealing pressure monitoring mechanism includes a sealing gasket, which is uniformly and symmetrically arranged in a sealing sleeve. An airbag ring is symmetrically fixedly installed at the bottom of the sealing gasket. The end of the airbag ring away from the sealing gasket is fixedly installed on the sealing sleeve. A duct is installed near the center of the sealing gasket on the sealing sleeve, with one end of the duct fixedly connected to the airbag ring and the other end fixedly connected to an air pump. The air pump is installed on the sealing sleeve. The airbag ring and the sealing sleeve have a certain degree of sealing. A sealing gasket is installed on the upper surface of the sealing sleeve for sealing connection between the sealing sleeves. A detection and stabilizing block is symmetrically slidably installed in the middle of the sealing sleeve. A sealing gasket is provided between the detection and stabilizing block and the sealing sleeve. A connecting plate is fixedly installed at the end of the detection and stabilizing block away from the sealing sleeve. A first monitor and a second monitor are respectively installed at both ends of the connecting plate. The first and second monitors are respectively installed in a first retainer. The connecting plate and the second monitor are respectively connected to the detection and stabilizing blocks at both ends of the connecting plate via probes for ultrasonic monitoring inside the pipeline.

[0016] Preferably, the linkage control early warning and protection mechanism includes a pneumatic cylinder, which is fixedly installed in a sealing sleeve, providing a certain degree of sealing between the pneumatic cylinder and the sealing sleeve. A pneumatic sealing plug is slidably installed on the inner wall of the pneumatic sealing plug, and the end of the pneumatic sealing plug away from the sealing sleeve is fixedly installed in the middle of a connecting plate, providing a certain degree of sealing between the pneumatic sealing plug and the inner wall of the pneumatic cylinder. A pneumatic linkage chamber is fixedly connected to one side of the middle of the pneumatic cylinder, and a piston resistance rod is slidably installed on the inner wall of the pneumatic linkage chamber. A measuring plate is slidably installed on the middle of the outer surface of the piston resistance rod, and the measuring plate is used for piston resistance rod displacement monitoring. A monitoring instrument is installed on the end of the measuring plate away from the piston resistance rod, and the bottom of the monitoring instrument is installed in a first retainer. A buffer spring is fixedly installed on the end of the piston resistance rod away from the pneumatic linkage chamber, and the end of the buffer spring away from the piston resistance rod is fixedly installed on the pneumatic linkage chamber. A transmission module and a power supply module are respectively provided on both sides of the monitoring instrument, and both the transmission module and the power supply module are installed in the sealing sleeve.

[0017] Compared with the prior art, the adaptive monitoring method for leakage of coal-fired soot blowers provided by the present invention has the following beneficial effects: (1) Integration of multiple monitoring dimensions to achieve accurate identification of leaks throughout the entire lifecycle; This solution overcomes the limitations of existing single-parameter monitoring technologies by constructing a comprehensive monitoring system through a three-dimensional approach: sealing pressure monitoring, pipeline ultrasonic monitoring, and pressure-displacement linkage monitoring. This enables accurate identification of leaks in sootblower pipelines throughout their entire lifecycle, from minor leaks to severe leaks. The sealing pressure monitoring mechanism forms a sealed monitoring chamber through an airbag ring and a sealing gasket, capturing minute changes in pressure within the chamber caused by a leak. The first and second monitoring instruments achieve real-time ultrasonic monitoring inside the pipeline through a pressure stabilizing block, identifying ultrasonic parameter fluctuations caused by steam turbulence resulting from the leak. The linkage control and early warning protection mechanism converts pressure changes into mechanical displacement through a pressure cylinder and a piston resistance rod, quantifying the degree of leakage. The triple monitoring data mutually verify and support each other, effectively eliminating the problem of single monitoring being susceptible to fluctuations in operating conditions and equipment vibration interference. Even initial minor leaks can be accurately detected, solving the core defects of existing technologies such as missed detections and false alarms.

[0018] (2) Adaptive sealing and working condition matching, suitable for complex operating environments; The airbag ring adaptive sealing structure designed in this scheme has stronger environmental adaptability and sealing stability compared to the simple rigid sealing methods of existing technologies. An air pump can inflate the airbag ring through an air pipe, causing the airbag ring to press tightly against the sealing gasket and fit seamlessly against the outer wall of the pipeline. This not only allows for adaptive adjustment of the sealing degree based on the deformation characteristics of the pipeline due to thermal expansion and contraction, but also compensates for sealing gaps caused by strong vibrations on site, ensuring the airtightness of the monitoring chamber. Simultaneously, the monitoring system can adaptively adjust the parameter thresholds of ultrasonic monitoring and the sensitivity of displacement monitoring based on real-time changes in steam pressure and temperature during the start-up and shutdown of the sootblower. This perfectly adapts to the complex operating conditions of high temperature, high dust, and pressure fluctuations around the furnace of a coal-fired boiler, avoiding the data distortion problems caused by changes in operating conditions in existing monitoring equipment and significantly improving the reliability of monitoring results.

[0019] (3) Automated linkage early warning to achieve rapid response and hierarchical control of leaks; This solution integrates the sealing pressure monitoring mechanism with the linkage control and early warning protection mechanism into a unified system, completely resolving the issues of disconnect between monitoring and early warning, and delayed response in existing technologies. When a pressure change occurs in the monitoring chamber due to leakage, it directly pushes the pressure sealing plug inside the pressure cylinder to move, thereby causing the connecting plate and piston resistance rod to move synchronously. The measuring plate captures the displacement of the piston resistance rod in real time and transmits it to the monitoring instrument. After the monitoring instrument combines the ultrasonic monitoring data to determine the degree of leakage, it automatically issues graded early warning signals through its own transmission module. A first-level early warning is triggered for minor leaks, prompting close attention; a second-level early warning is triggered for severe leaks, and the sootblower control system can be linked to issue a shutdown suggestion. The entire process requires no manual intervention, achieving automation and integration from leak identification to early warning response, significantly shortening the response time for leak handling, and effectively preventing the leak from escalating and causing secondary failures.

[0020] (4) The integrated structural design reduces operation and maintenance costs and improves installation adaptability; This solution integrates the sealing pressure monitoring mechanism and the linkage control early warning and protection mechanism into a single structure consisting of a first clamp, a second clamp, and a sealing sleeve. Compared with the existing distributed monitoring equipment layout, it has significant advantages in terms of convenient installation and low operation and maintenance costs. The device, through its clamp-on design, can be directly fixed to flanges and interfaces where leakage is frequent in sootblower pipelines, without requiring large-scale modifications to the existing pipelines, and is compatible with different specifications of coal-fired sootblower pipelines. All monitoring elements (power elements, control elements) are integrated within the clamp and sealing sleeve, forming a closed protective space, effectively preventing corrosion and damage to the elements from dust and moisture around the furnace, and reducing the equipment failure rate. Simultaneously, the device is equipped with independent power supply and transmission modules, enabling independent data acquisition and transmission without relying on the complex central control system of the power plant. Later operation and maintenance only requires parameter calibration and fault reset through the control panel, significantly reducing the manpower and material costs of on-site operation and maintenance. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is an auxiliary schematic diagram of the three-dimensional structure of the present invention; Figure 3 This is a schematic diagram showing the structural disassembly and connection relationship between the sealed air pressure monitoring mechanism and the linkage control early warning and protection mechanism of the present invention. Figure 4 This is a schematic diagram of the structural connection relationship of the sealed air pressure monitoring mechanism of the present invention; Figure 5 This is an auxiliary schematic diagram showing the structural connection relationship of the sealed air pressure monitoring mechanism of the present invention; Figure 6 For the present invention Figure 5 Enlarged view of point A in the middle Figure 7 This is a schematic diagram of the structural connection relationship of the linkage control early warning and protection mechanism of the present invention; Figure 8 For the present invention Figure 7 Enlarged view at point B in the middle; Figure 9 This is a schematic diagram of the adaptive monitoring method for leakage in a coal-fired soot blower according to the present invention.

[0022] In the picture: 1. First retaining cover; 11. Second retaining cover; 12. Control panel; 13. Sealing sleeve; 2. Sealing pressure monitoring mechanism; 21. Sealing gasket; 22. Airbag ring; 23. Air pump; 24. Detection and pressure stabilizing block; 25. Connecting plate; 26. First monitoring instrument; 27. Second monitoring instrument; 3. Linkage control early warning and protection mechanism; 31. Pneumatic cylinder; 32. Pneumatic sealing plug; 33. Return spring; 34. Pneumatic linkage chamber; 35. Piston resistance rod; 36. Buffer spring; 37. Measuring plate; 38. Monitoring instrument. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0024] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0025] Example 1, please refer to Figures 1 to 9 As shown: To address the problems mentioned in the technical solutions, this application provides an adaptive monitoring method for leakage in a coal-fired soot blower, including a first cover 1, a second cover 11 mounted on one side of the first cover 1, and a control panel 12 mounted on the side of the first cover 1 opposite to the second cover 11; sealing sleeves 13 are correspondingly installed on both the first cover 1 and the second cover 11, and the adaptive monitoring device for leakage in the coal-fired soot blower also includes a sealing air pressure monitoring mechanism 2 and a linkage control early warning and protection mechanism 3.

[0026] Among them, the sealing air pressure monitoring mechanism 2 is set inside the sealing sleeve 13, mainly used to realize the multiple protection monitoring functions when the pipeline leaks; the linkage control early warning protection mechanism 3 is set inside the first cover 1, mainly used to realize the automatic early warning and protection control after leakage.

[0027] The first retaining cover 1 is fitted with a second retaining cover 11 on one side, and the first retaining cover 1 can be fixed to the second retaining cover 11 with a nut to achieve a seal. Furthermore, this solution is not limited to tee pipes; it can be customized for various pipe structures.

[0028] like Figures 1 to 5As shown, the sealing pressure monitoring mechanism 2 includes a sealing gasket 21, which is evenly and symmetrically arranged inside the sealing sleeve 13. An airbag ring 22 is symmetrically fixedly installed at the bottom of the sealing gasket 21, and the end of the airbag ring 22 away from the sealing gasket 21 is fixedly connected to the inner wall of the sealing sleeve 13. An air guide tube is installed near the middle of the sealing sleeve 13, with one end fixedly connected to the airbag ring 22 and the other end fixedly connected to an air pump 23, which is fixedly installed on the sealing sleeve 13. The airbag ring 22 and the sealing sleeve 13 maintain a good seal. A sealing gasket is also fitted on the upper surface of the sealing sleeve 13 to achieve a sealed connection between adjacent sealing sleeves 13.

[0029] A detection and stabilizing block 24 is symmetrically slidably installed in the middle of the sealing sleeve 13. A sealing gasket is provided at the contact point between the detection and stabilizing block 24 and the sealing sleeve 13 to ensure sealing. A connecting plate 25 is fixedly installed at the end of the detection and stabilizing block 24 away from the sealing sleeve 13. A first monitoring instrument 26 and a second monitoring instrument 27 are respectively configured at both ends of the connecting plate 25, and both the first monitoring instrument 26 and the second monitoring instrument 27 are installed inside the first retaining cover 1. The connecting plate 25 and the second monitoring instrument 27 are respectively connected to the detection and stabilizing block 24 at both ends of the connecting plate 25 through probes, thereby realizing ultrasonic monitoring of the inside of the pipeline.

[0030] like Figures 4 to 8 As shown, the linkage control early warning and protection mechanism 3 includes a pneumatic cylinder 31, which is installed inside the sealing sleeve 13 and maintains a good seal between the pneumatic cylinder 31 and the sealing sleeve 13. A pneumatic sealing plug 32 is slidably installed on the inner wall of the pneumatic cylinder 31. The end of the pneumatic sealing plug 32 away from the sealing sleeve 13 is fixedly connected to the middle of the connecting plate 25, and a good seal is maintained between the pneumatic sealing plug 32 and the inner wall of the pneumatic cylinder 31.

[0031] A pneumatic linkage chamber 34 is fixedly connected to one side of the middle of the pneumatic cylinder 31. A piston resistance rod 35 is slidably installed on the inner wall of the pneumatic linkage chamber 34, and a measuring plate 37 is slidably installed on the middle of the outer surface of the piston resistance rod 35. The measuring plate 37 is used to monitor the displacement of the piston resistance rod 35 in real time. A monitoring instrument 38 is installed at the end of the measuring plate 37 away from the piston resistance rod 35, and the bottom of the monitoring instrument 38 is fixedly installed inside the first cover 1. A buffer spring 36 is fixedly connected to the end of the piston resistance rod 35 away from the pneumatic linkage chamber 34, and the end of the buffer spring 36 away from the piston resistance rod 35 is fixedly connected to the inner wall of the pneumatic linkage chamber 34. In addition, a transmission module and a power supply module are respectively configured on both sides of the monitoring instrument 38, and both the transmission module and the power supply module are installed inside the sealing sleeve 13.

[0032] The linkage measurement of this device revolves around the core linkage logic of "air pressure change - mechanical displacement - electrical signal acquisition - early warning output", realizing precise linkage and data synchronization between various mechanisms and components. The specific linkage measurement process is as follows: 1. Mechanical linkage measurement between the sealing air pressure monitoring mechanism 2 and the linkage control early warning and protection mechanism 3: When a leak occurs in the sootblower pipeline, high-pressure steam seeps into the monitoring chamber formed by the sealing sleeve 13. The air pressure in the chamber rises, pushing the air pressure sealing plug 32 in the air pressure cylinder 31 to slide along the cylinder wall. The air pressure sealing plug 32 drives the detection and pressure stabilizing blocks 24 at both ends to move synchronously through the middle connecting plate 25. At the same time, the displacement of the connecting plate 25 will pull the piston resistance rod 35 in the air pressure linkage chamber 34 to compress the buffer spring 36, completing the accurate conversion of air pressure signal into mechanical displacement signal. In this process, the accuracy of mechanical linkage is verified by measuring the linear relationship between the displacement of the air pressure sealing plug 32 and the air pressure change value in the monitoring chamber, ensuring that the air pressure change can be converted into mechanical displacement without loss.

[0033] 2. Linked Measurement of Mechanical Displacement and Electrical Signal Acquisition: During the displacement of the piston resistance rod 35, the measuring plate 37 on its outer surface captures the displacement in real time and converts the mechanical displacement signal into an electrical signal, which is then transmitted to the monitoring instrument 38. Simultaneously, the displacement of the detection stabilizing block 24 causes the ultrasonic probe to remain in contact with the inner wall of the pipe. The first and second monitoring instruments 3827 synchronously transmit the acquired ultrasonic propagation parameter electrical signals to the monitoring instrument 38. The monitoring instrument 38 synchronously receives and fuses the two electrical signals. By measuring the synchronization of the displacement electrical signal and the ultrasonic electrical signal acquisition and the data transmission delay rate, the linkage efficiency of the electrical signal acquisition is verified, ensuring that there is no delay or asynchronous deviation between the two signals.

[0034] 3. Linked Measurement of Electrical Signal Analysis and Early Warning Output: The monitor 38 has preset air pressure displacement thresholds and ultrasonic parameter reference values. When the received electrical signal exceeds the preset threshold, the internal analysis program is immediately activated to determine the leakage level and transmit the signal to the transmission module. The transmission module synchronously sends the early warning signal, leakage location, leakage degree, and other data to the terminal industrial control computer and the on-site warning device, completing the linkage between electrical signal analysis and early warning output. During this process, the accuracy of the linked early warning output is verified by measuring the time difference between the electrical signal exceeding the limit and the early warning signal being issued, and the matching degree between the early warning level and the actual leakage degree. This ensures that different levels of leakage can trigger corresponding early warning actions, and that the early warning information is accurate and without deviation.

[0035] 4. Full-process linkage closed-loop measurement: After the device completes the early warning, if the maintenance personnel perform a fault reset operation through the control panel 12, the power supply module will simultaneously send a reset signal to the air pump 23 and each monitoring instrument 38. The air pump 23 starts the depressurization and inflation program, causing the air pressure sealing plug 32 and the piston resistance rod 35 to return to their initial positions. Each monitoring instrument 38 automatically recalibrates the reference value and enters the monitoring state, forming a linkage closed loop of "monitoring-early warning-reset-remonitoring". By measuring the position recovery accuracy of each component after reset and the calibration accuracy of the monitoring reference value, the integrity of the full-process linkage closed loop is verified, ensuring that the device can quickly return to normal monitoring state after fault handling and achieve continuous adaptive monitoring.

[0036] Overall, the device's linkage measurement covers the entire process of mechanics, electrical signals, and control outputs. A seamless linkage system is formed between various mechanisms and components. All measurement processes are adaptively adjusted based on the actual operating conditions of the sootblower to ensure the accuracy, efficiency, and closed-loop nature of the linkage. This is the core technical support for the solution to achieve adaptive leakage monitoring.

[0037] Example 2: Based on Embodiment 1, but with some differences, the adaptive monitoring method for leakage in a coal-fired soot blower proposed in this invention is described below with reference to specific examples and accompanying drawings. The specific content is as follows: This embodiment is applied to the monitoring scenario of steam soot blower pipeline in the furnace of a 300MW coal-fired power unit boiler. The soot blower is a conventional ash removal device for boilers. Its steam transmission pipeline is under high temperature and high pressure conditions for a long time. The pipeline interface and seal are prone to micro-leakage due to thermal expansion and contraction and media erosion. If it is not detected in time, it will cause steam waste and reduced furnace thermal efficiency. In severe cases, the leaked steam will come into contact with low temperature components, causing condensation corrosion and even affecting the normal operation of the boiler.

[0038] The monitoring device in this solution is installed at the connecting flange of the main steam pipeline and the branch pipeline of the sootblower, which is a high-risk leakage point. The first and second clamps of the device are fixed to the outside of the pipeline by bolts, and the sealing sleeve is fitted to the outer wall of the pipeline to achieve a seal. The entire device is powered by the boiler auxiliary control system, and the monitoring data is transmitted to the industrial control computer in the auxiliary control room in real time to realize real-time monitoring and automatic early warning of leakage. It is adapted to the operating conditions of sootblower start-up and shutdown, steam pressure fluctuation range of 0.8-1.5MPa, and furnace temperature change range of 300-800℃, and completes adaptive monitoring of micro-leakage identification, leakage degree determination, and multi-level early warning.

[0039] This plan outlines the specific operational monitoring methods and procedures. This monitoring method is based on a matching sealing pressure monitoring mechanism and a linkage control and early warning protection mechanism. Its core functionality utilizes a triple adaptive monitoring logic combining sealed cavity pressure monitoring, pipeline ultrasonic monitoring, and pressure-displacement linkage monitoring to accurately identify and warn of leaks in the sootblower pipeline. The specific operation and monitoring steps are divided into four stages: device installation and commissioning, normal operation monitoring, leak identification and early warning, and fault reset and recovery. The operation and monitoring logic for each stage are as follows: Phase 1: Single operation for device installation and commissioning; after completion, long-term monitoring begins. Device fixing and sealing assembly; The first clip 1 and the second clip 11 are fastened to the flange of the pipe to be monitored by the soot blower and tightened with bolts so that the sealing sleeve 13 fits tightly against the outer wall of the pipe; the sealing sleeves 13 are sealed together by the sealing gaskets on their surfaces to form an independent sealed monitoring chamber.

[0040] Initialize the air pressure monitoring mechanism; Start the air pump 23 and inflate the airbag ring 22 through the air guide tube, so that the airbag ring 22 expands and presses against the sealing gasket 21, allowing the sealing gasket 21 to fit seamlessly with the outer wall of the pipe, thereby enhancing the sealing performance of the monitoring chamber; after inflation is complete, turn off the air pump 23 and confirm that there is no air pressure leakage between the airbag ring 22 and the sealing sleeve 13.

[0041] Calibration and linkage debugging of monitoring components; ① Start the first monitor 26 and the second monitor 27, and attach their ultrasonic probes to the inner wall of the pipe through the detection and pressure stabilizing block 24 to calibrate the ultrasonic propagation parameters inside the pipe when there is no leakage in the ultrasonic monitoring reference value; ② Start the monitoring instrument 38, adjust the displacement monitoring accuracy of the measuring board 37 on the piston resistance rod 35, set the initial position of the piston resistance rod 35 in the pneumatic linkage chamber 34 as the displacement zero point, and the buffer spring 36 is in a naturally extended state. ③ Turn on control panel 12, link the power supply module and transmission module, confirm that all monitoring data such as air pressure, ultrasound and displacement can be transmitted normally to the terminal industrial control computer, and complete the device initialization and debugging.

[0042] Phase Two: Adaptive monitoring of the entire sootblower operation process during normal operation, with real-time continuous monitoring. After the soot blower is started, high-pressure steam of 0.8-1.5MPa is introduced into the steam pipeline, and the device enters normal monitoring mode. All mechanisms work together to achieve adaptive real-time monitoring. The core operation and monitoring logic are as follows: Basic monitoring of sealed air pressure; The sealed monitoring chamber formed between the sealing sleeve 13 and the pipeline is a closed space. When there is no leakage, the air pressure in the monitoring chamber remains stable. The air pump 23 is in standby mode, and the airbag ring 22 continues to maintain a sealed state, providing a stable sealing environment for the monitoring chamber.

[0043] Precise ultrasonic monitoring inside pipelines; The first monitoring instrument 26 and the second monitoring instrument 27 continuously emit ultrasonic waves into the pipeline and receive reflected waves through the probe on the pressure stabilizing block 24, and collect parameters such as ultrasonic propagation speed and amplitude inside the pipeline in real time. The device adaptively adjusts the parameter threshold of ultrasonic monitoring according to the real-time changes in steam pressure and temperature inside the pipeline, and eliminates the interference of operating condition fluctuations on the monitoring results.

[0044] Pressure displacement linkage auxiliary monitoring; When there is no leakage, the air pressure in the sealed monitoring chamber remains unchanged, the air pressure sealing plug 32 in the air pressure cylinder 31 remains stationary, the piston resistance rod 35 has no displacement, the displacement value monitored by the measuring plate 37 is always zero, and the monitoring instrument 38 continuously collects and uploads the reference displacement data.

[0045] Data fusion and adaptive analysis; The terminal industrial control computer receives real-time air pressure data, ultrasonic monitoring data, and air pressure displacement data from the sealed cavity. Through the fusion analysis of these three data, it determines whether the pipeline is in a normal state. If a single data point shows a slight fluctuation, the device automatically increases the sampling frequency of the other two monitoring points to achieve adaptive monitoring enhancement and eliminate false judgments caused by external interference such as slight vibrations in the pipeline.

[0046] Phase 3: Leakage Identification and Tiered Early Warning Automatically triggered upon detection of a leak. When a minor or severe leak occurs in the sootblower pipeline, the air pressure in the sealed monitoring chamber changes, triggering a coordinated response from the triple monitoring mechanism. The device automatically identifies the leak, determines its severity, and issues a graded warning. The specific operation and logic are as follows: Micro-leakage identification: Leakage rate < 0.05 MPa / min When a micro-leak occurs in the pipeline, high-pressure steam permeates from the leak point into the sealed monitoring chamber, causing the gas pressure inside the chamber to rise slowly. The gas pressure pushes the gas pressure sealing plug 32 inside the gas pressure cylinder 31 to slide outward, causing the connecting plate 25 and the detection pressure stabilizing block 24 to move slightly. This, in turn, pulls the piston resistance rod 35 in the gas pressure linkage chamber 34 to compress the buffer spring 36. The measuring plate 37 detects the tiny displacement of the piston resistance rod 35 (0.5-2 mm) and transmits it to the monitoring instrument 38. At the same time, the steam turbulence generated by the leak causes the ultrasonic propagation parameters inside the pipeline to deviate from the reference value, and the first and second monitoring instruments capture this change.

[0047] Warning Action: The device determines that there is a minor leak. The terminal industrial control computer issues a level one warning sound and light alarm in green. The transmission module sends the leak location and initial leak data to the auxiliary control room to remind maintenance personnel to pay close attention.

[0048] Severe leak identification: Leakage rate ≥ 0.05 MPa / min; When a significant leak occurs in the pipeline, the air pressure inside the sealing monitoring chamber rises rapidly, the air pressure sealing plug 32 shifts significantly, the piston resistance rod 35 shifts by more than 2 mm, and the measuring plate 37 detects a sharp change in the displacement value; at the same time, the ultrasonic propagation parameters inside the pipeline deviate significantly, and the air pressure data in the sealing chamber also shows a rapid upward trend.

[0049] Warning Action: The device determines a severe leak through cross-validation of three data points. The terminal industrial control computer issues a level two warning audible and visual alert in red and sends a signal to the sootblower control system via the linkage control module, suggesting that the sootblower be shut down. At the same time, the transmission module continuously uploads the leakage level and real-time data to provide a basis for maintenance personnel to carry out emergency repairs.

[0050] Precise location of the leak; The first monitoring instrument 26 and the second monitoring instrument 27 correspond to the two ends of the pipeline monitoring section, respectively. By comparing the ultrasonic parameter change time and amplitude attenuation of the two monitoring instruments, and combining the displacement direction of the piston resistance rod 35, the device can adaptively determine the precise location of the leak point with an error range of ≤5cm.

[0051] Phase Four: Fault Reset and Device Restoration - Operations After Leakage Fault Handling Leakage troubleshooting; Based on the device's early warning information and leak location, maintenance personnel shut down the faulty soot blower and performed repair operations such as welding and replacing seals at the pipeline leak point. After completion, the pipeline was restored to its normal sealing state.

[0052] Device pressure relief and reset; The control panel 12 opens the pressure relief valve of the sealed monitoring chamber to release the residual air pressure in the chamber, so that the air pressure sealing plug 32 in the air pressure cylinder 31 returns to its initial position under the action of the reset spring 33, and the piston resistance rod 35 returns to the zero displacement point under the elastic force of the buffer spring 36. The measuring plate 37 recalibrates the displacement reference value.

[0053] Monitoring system restart and verification; Restart the air pump 23 to inflate the airbag ring 22 and restore the sealing of the monitoring chamber; restart the first and second monitors and monitor 38, collect new ultrasonic, air pressure and displacement reference values, and after confirming that all monitoring data have returned to normal, the device re-enters the normal operation monitoring mode and completes the fault reset.

[0054] The core adaptive capability of this method permeates the entire monitoring process and is mainly reflected in three aspects: Adaptive operating conditions: Based on the real-time changes in steam pressure and temperature in the sootblower pipeline, the parameter thresholds of ultrasonic monitoring are automatically adjusted to eliminate the interference of operating condition fluctuations on the monitoring results. Adaptive monitoring accuracy: When fluctuations occur in a single monitoring data point, the sampling frequency of the other two monitoring points is automatically increased to enhance monitoring accuracy and avoid misjudgments; Adaptive warning level: Based on the magnitude of the leak, the system determines the rate of change in air pressure and the amount of displacement, automatically triggering different levels of warnings to achieve graded control of the leak.

[0055] Please refer to the above work process. Figures 1 to 9 .

[0056] It should be noted that the term "comprising" or any other variation thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0057] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An adaptive monitoring method for leakage in a coal-fired soot blower, characterized in that, Based on an adaptive monitoring device for coal-fired sootblower leakage, the aforementioned adaptive monitoring method for coal-fired sootblower leakage achieves accurate leakage identification and early warning through a triple adaptive monitoring logic of sealed cavity air pressure monitoring, pipeline ultrasonic monitoring, and air pressure displacement linkage monitoring. The method comprises four stages: device installation and commissioning, normal operation monitoring, leakage identification and early warning, and fault reset and recovery. The specific steps are as follows: S1. Device installation and commissioning: Fasten the first clip (1) and the second clip (11) to the flange of the pipe to be monitored by the soot blower and tighten them so that the sealing sleeve (13) fits against the outer wall of the pipe to form a sealed monitoring cavity; start the air pump (23) to inflate the air bag ring (22) to enhance the sealing performance of the sealed monitoring cavity; calibrate the ultrasonic monitoring reference values ​​of the first monitor (26) and the second monitor (27), adjust the displacement monitoring accuracy of the measuring board (37) on the piston resistance rod (35) and set the displacement zero point, turn on the control panel (12) to confirm that the monitoring data can be transmitted normally to the terminal industrial control computer; S2. Normal operation monitoring: After the soot blower is started, the device enters the normal monitoring mode. The sealed monitoring chamber maintains stable air pressure. The first monitor (26) and the second monitor (27) collect the ultrasonic propagation parameters inside the pipeline in real time and adaptively adjust the ultrasonic monitoring parameter threshold according to the changes in steam pressure and temperature. The air pressure sealing plug (32) inside the air pressure cylinder (31) remains stationary and the piston resistance rod (35) has no displacement. The terminal industrial control computer performs fusion analysis on the air pressure, ultrasonic and displacement data. When a single data fluctuates, the sampling frequency of the other two monitoring devices is automatically increased. S3. Leakage Identification and Early Warning: When a pipeline leaks, high-pressure steam seeps into the sealed monitoring chamber, causing a change in the gas pressure inside the chamber. This pushes the gas pressure sealing plug (32) to move and drives the connecting plate (25), the detection pressure stabilizing block (24), and the piston resistance rod (35) to move synchronously. The measuring plate (37) captures the displacement of the piston resistance rod (35), and the first monitoring instrument (26) and the second monitoring instrument (27) capture the changes in ultrasonic propagation parameters. The terminal industrial control computer determines the leakage level and triggers a graded early warning through cross-validation of three data. At the same time, it determines the leakage location based on the difference in parameter changes of the two ultrasonic monitoring instruments and the displacement direction of the piston resistance rod (35). The error range is ≤5cm. Among them, a leakage amount <0.05MPa / min is a micro-leakage, triggering a first-level early warning; a leakage amount ≥0.05MPa / min is a severe leak, triggering a second-level early warning and sending a shutdown suggestion to the sootblower control system. S4. Fault Reset and Recovery: After the maintenance personnel complete the repair of the leak point, they operate the control panel (12) to discharge the residual air pressure in the sealing monitoring chamber, so that the air pressure sealing plug (32) and piston resistance rod (35) return to their initial positions and recalibrate the displacement reference value; the air pump (23) is restarted to inflate the airbag ring (22) to restore the sealing performance, and each monitoring instrument is restarted and new reference values ​​are collected. After confirming that the data is normal, the device re-enters the normal operation monitoring mode.

2. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 1, characterized in that, In S1, the first clip (1) and the second clip (11) are fastened by bolts, and the sealing sleeve (13) is sealed by the sealing gasket on the surface. After inflation, it is necessary to confirm that there is no air pressure leakage between the airbag ring (22) and the sealing sleeve (13).

3. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 1, characterized in that, The ultrasonic monitoring parameters mentioned in S2 include ultrasonic propagation speed and amplitude. The device is adapted to the operating conditions of steam pressure fluctuation of 0.8-1.5MPa and furnace temperature fluctuation of 300-800℃ during the start-up and shutdown of the sootblower.

4. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 1, characterized in that, When there is a minor leak in S3, the displacement of the piston resistor rod (35) is 0.5-2mm. The first-level warning is a green audible and visual warning, and the transmission module sends the leak location and initial data to the auxiliary control room. When there is a severe leak, the displacement of the piston resistor rod (35) exceeds 2mm. The second-level warning is a red audible and visual warning, and the transmission module continuously uploads the leak level and real-time data.

5. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 1, characterized in that, The adaptive capability of the method is reflected in: adapting to the working condition based on the real-time changes in steam pressure and temperature in the sootblower pipeline; automatically increasing the sampling frequency of the other two monitoring devices when a single monitoring data fluctuates to achieve adaptive monitoring accuracy; and automatically triggering different levels of early warning based on the size of the leakage to achieve adaptive early warning level.

6. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 1, characterized in that, The adaptive monitoring device for leakage of a coal-fired soot blower includes a first cover (1), a second cover (11) installed on one side of the first cover (1), a control panel (12) installed on the side of the first cover (1) away from the second cover (11), and sealing sleeves (13) respectively installed on the first cover (1) and the second cover (11). The adaptive monitoring device for leakage of a coal-fired soot blower also includes a sealing air pressure monitoring mechanism (2) and a linkage control early warning and protection mechanism (3). The sealing pressure monitoring mechanism (2) is installed in the sealing sleeve (13), and the sealing pressure monitoring mechanism (2) is used for multiple protection monitoring when the pipeline leaks; The linkage control early warning protection mechanism (3) is installed in the first card cover (1) and is used for automatic early warning.

7. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 6, characterized in that, The sealing pressure monitoring mechanism (2) includes a sealing gasket (21), which is uniformly and symmetrically arranged in the sealing sleeve (13). An airbag ring (22) is symmetrically fixedly installed at the bottom of the sealing gasket (21). The end of the airbag ring (22) away from the sealing gasket (21) is fixedly installed on the sealing sleeve (13). A duct is installed on the sealing sleeve (13) near the middle of the sealing gasket (21), with one end of the duct fixedly connected to the airbag ring (22) and the other end fixedly connected to an air pump (23). The air pump (23) is installed on the sealing sleeve (13). The airbag ring (22) and the sealing sleeve (13) have a certain degree of sealing. A sealing gasket is installed on the upper surface of the sealing sleeve (13). For the sealing connection between the sealing sleeve (13), a detection and stabilizing block (24) is symmetrically slidably installed in the middle of the sealing sleeve (13). A sealing gasket is provided between the detection and stabilizing block (24) and the sealing sleeve (13). A connecting plate (25) is fixedly installed at the end of the detection and stabilizing block (24) away from the sealing sleeve (13). A first monitoring instrument (26) and a second monitoring instrument (27) are respectively provided at both ends of the connecting plate (25). The first monitoring instrument (26) and the second monitoring instrument (27) are respectively installed in the first cover (1). The connecting plate (25) and the second monitoring instrument (27) are respectively connected to the detection and stabilizing block (24) at both ends of the connecting plate (25) through probes for ultrasonic monitoring inside the pipeline.

8. The adaptive monitoring method for leakage in a coal-fired soot blower according to claim 7, characterized in that, The linkage control early warning and protection mechanism (3) includes a pneumatic cylinder (31), which is fixedly installed in a sealing sleeve (13). The pneumatic cylinder (31) and the sealing sleeve (13) have a certain degree of sealing. A pneumatic sealing plug (32) is slidably installed on the inner wall of the pneumatic sealing plug (32). The end of the pneumatic sealing plug (32) away from the sealing sleeve (13) is fixedly installed in the middle of the connecting plate (25). The pneumatic sealing plug (32) and the inner wall of the pneumatic cylinder (31) have a certain degree of sealing. A pneumatic linkage chamber (34) is fixedly connected to one side of the middle of the pneumatic cylinder (31). A piston resistance rod (35) is slidably installed on the inner wall of the pneumatic linkage chamber (34). A measuring plate (37) is slidably mounted on the middle of the outer surface of the resistance rod (35). The measuring plate (37) is used for displacement monitoring of the piston resistance rod (35). A monitoring instrument (38) is mounted on the end of the measuring plate (37) away from the piston resistance rod (35). The bottom of the monitoring instrument (38) is installed in the first cover (1). A buffer spring (36) is fixedly mounted on the end of the piston resistance rod (35) away from the pneumatic linkage chamber (34). The end of the buffer spring (36) away from the piston resistance rod (35) is fixedly mounted on the pneumatic linkage chamber (34). A transmission module and a power supply module are respectively provided on both sides of the monitoring instrument (38). The transmission module and the power supply module are both installed in the sealing sleeve (13).

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