Boiler Load Analysis Using Damper Opening Sensors
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Solution Overview
Problem
Existing boiler load analysis methods face challenges in accurately measuring steam load due to variations in drive motor current and the need for specific current sensors, which are costly and time-consuming to select, especially in boilers with dampers for air flow regulation.
Innovation Solution
A boiler load analysis apparatus that includes an opening sensor to measure the opening degree of fuel and air flow regulating mechanisms, allowing for accurate calculation of steam load using a tilt sensor or clamp current sensor, enabling retrofitting of existing boilers without requiring expensive flowmeters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flowmeter is used to measure steam generation amount, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses intermediate parameters (current value from drive motor, pressure from pressure sensor) as mediators to indirectly measure steam generation amount. Instead of directly measuring steam flow with a complex flowmeter, the system measures electrical current and pressure, which are easier to obtain and process, while still providing accurate steam load information through calculation relationships.
Solution Approach 2:
The patent replaces the mechanical flowmeter system with an electrical measurement system. By measuring the current value supplied to the drive motor and combining it with pressure sensor data, the system substitutes a simple electrical sensor arrangement for a complex mechanical flow measurement device, reducing both complexity and cost while maintaining measurement capability.
2Device complexity
If current value of drive motor is measured to analyze boiler load, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent merges multiple measurement parameters (current value from drive motor and pressure from pressure sensor) into a combined analysis system. By combining these two measurements rather than relying on current alone, the system achieves accurate steam load analysis while keeping the device configuration simple. The combination of parameters compensates for the limitations of individual measurements.
3Adaptability or versatility
If a general-purpose current sensor is used for drive motor measurement, then adaptability is improved, but measurement precision deteriorates due to smaller current variation
Solution Approach 1:
The pressure sensor acts as an additional intermediary parameter that enhances the measurement system. When combined with the current sensor data, it provides a more robust basis for steam load calculation, compensating for the limited precision from current measurement alone and enabling accurate analysis even with general-purpose sensors.
4Adaptability or versatility
If damper is added to regulate air flow, then boiler control flexibility is improved, but measurement of steam load becomes more difficult
Solution Approach 1:
The system uses feedback from the pressure sensor and current sensor to continuously monitor and analyze steam load conditions. The feedback mechanism allows the system to account for variations caused by damper operations, maintaining accurate measurement capability despite the added complexity of air flow regulation. The feedback loop enables real-time adjustment and accurate tracking of steam load changes.
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
The apparatus achieves highly accurate and efficient boiler load analysis with a simple configuration, applicable to boilers of various capacities, ensuring safe and cost-effective operation by directly measuring the opening degree of damper mechanisms.
Implementation Method 1
an opening sensor provided to at least one of a fuel supply line and a combustion air supply line of the boiler and configured to measure an opening degree of at least one of a fuel flow regulating mechanism configured to regulate, with the opening degree, a fuel flow in the fuel supply line and a supplied air flow regulating mechanism configured to regulate, with the opening degree, a supplied air flow in the combustion air supply line
Implementation Method 2
The pressure sensor detects pressure in the boiler body
Data Source
AI summary
The invention provides a boiler load analysis apparatus that has a simple configuration and achieves highly accurate analysis of a boiler load. A boiler load analysis apparatus (10) includes an opening sensor (15) provided to at least one of a fuel supply line (45) and a combustion air supply line (50) of a boiler (40) and configured to measure an opening degree of at least one of a fuel flow regulating mechanism (47) configured to regulate, with the opening degree, a fuel flow in the fuel supply line (45) and a supplied air flow regulating mechanism (54) configured to regulate, with the opening degree, a supplied air flow in the combustion air supply line (50), and a load analyzer (20) configured to calculate a steam load of the boiler (40) from a measurement value of the opening sensor (15), to analyze the steam load of the boiler (40).