Boiler Combustion Monitoring Through Membrane Penetrations
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Solution Overview
Problem
Existing methods for monitoring combustion properties in boilers with parallel steam tubes separated by a metal membrane require costly and time-consuming reconfiguration of steam tubes to provide optical access, limiting frequent and efficient combustion monitoring.
Innovation Solution
A method and apparatus that project a beam of light through elongated penetrations in the metal membrane between steam tubes without relocating the tubes, using a pitch and catch optic configuration with relay lenses and alignment mechanisms to maximize light strength and alignment precision, allowing for continuous monitoring without shutting down the boiler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If tube bends are installed to provide optical access for TDLAS monitoring, then combustion property measurement capability is improved, but installation complexity and cost increase significantly
Solution Approach 1:
The optical path is segmented into multiple sections using relay lenses. The first relay lens creates an intermediate image, and the second relay lens transfers this image to the detector, breaking down the complex optical path into manageable segments that can be installed through small penetrations rather than requiring large tube bends
Solution Approach 2:
Relay lenses are introduced as intermediary optical elements between the boiler interior and the detector. These relay lenses act as mediators that transfer the optical information through the metal membrane penetrations without requiring direct line-of-sight access, thereby eliminating the need for complex tube bend configurations
2Difficulty of detecting and measuring
If tube bends are installed to provide optical access, then combustion monitoring capability is improved, but installation time and operational disruption increase
Solution Approach 1:
The penetrations in the metal membrane are pre-configured with appropriate dimensions and positions before the relay lenses are installed. This preliminary preparation allows for quick installation of the optical components without requiring time-consuming tube bend fabrication and installation, significantly reducing installation time and operational disruption
3Strength
If small penetrations are used in the metal membrane, then structural integrity is improved, but optical access quality deteriorates
Solution Approach 1:
The mechanical tube bend system is replaced with an optical relay lens system. The relay lenses use optical principles (lens focusing and image transfer) to provide adequate optical access through small penetrations, eliminating the need for large structural openings that would compromise boiler wall integrity
4Adaptability or versatility
If multiple pitch/catch optic pairs are installed for multiplexed measurement, then measurement coverage is improved, but number of penetrations and installation complexity increase
Solution Approach 1:
The relay lens configuration is designed as a universal, reusable module that can be replicated for multiple measurement paths. Each pitch/catch optic pair uses the same relay lens arrangement, allowing standardized installation across multiple locations without requiring unique custom solutions for each penetration, thereby reducing overall installation complexity despite increased measurement coverage
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and cost-effective combustion property monitoring by eliminating the need for tube bends, allowing for frequent and precise measurements without disrupting boiler operations.
Implementation Method 1
projecting a beam of light through a pitch optic comprising a pitch collimating lens and a pitch relay lens; receiving the beam of light with a catch optic comprising a catch relay lens and a catch collimating lens
Implementation Method 2
The pitch relay lens is optically coupled to the first penetration to project the beam into the boiler interior. The catch relay lens is optically coupled to the second penetration
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of monitoring combustion properties in an interior of a boiler of the type having walls comprising a plurality of parallel steam tubes separated by a metal membrane. First and second penetrations are provided in the metal membrane between adjacent tubes on opposite sides of the boiler. A beam of light is projected through a pitch optic comprising a pitch collimating lens and a pitch relay lens, both residing outside the boiler interior. The pitch relay lens projects the beam through a penetration into the boiler interior. The beam of light is received with a catch optic substantially identical to the pitch optic residing outside the boiler interior. The strength of the collimated received beam of light is determined. At least one of the pitch collimating lens and the catch collimating lens may then be aligned to maximize the strength of the collimated received beam.