Optical Fiber Erosion Monitoring Without Bragg Gratings
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Solution Overview
Problem
Current erosion monitoring systems in catalytic cracking plants, such as those with fluidized catalysts, face challenges in detecting erosion in internal components due to thermal insulation and complex geometries, leading to early internal damage before external thermal effects are detectable, and existing solutions like Bragg grid-based systems are economically demanding.
Innovation Solution
The use of optical fibers without a Bragg grid, integrated near the walls to be monitored, that measure erosion by analyzing light reflections or pulse travel time to determine the depth of erosion, integrated within the anti-erosion coating structures, allowing for continuous monitoring without relying on temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Bragg grid-based optical fiber sensors are used to monitor erosion, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the Bragg grid component from the optical fiber sensor system, using plain optical fibers instead. This removes the complex grating structure while maintaining erosion monitoring capability through light reflection principles, thereby reducing device complexity and cost while preserving measurement functionality.
Solution Approach 2:
The patent replaces expensive Bragg grid-based sensors with simpler, more economical optical fibers that can be easily installed and replaced. The plain optical fibers serve as disposable or replaceable components that provide sufficient measurement capability without the high cost and complexity of Bragg grid systems.
2Ease of operation
If thermal monitoring methods are used to detect erosion, then ease of operation is improved, but reliability deteriorates due to thermal insulation and geometry effects
Solution Approach 1:
The patent substitutes thermal monitoring with optical monitoring using light reflection principles. Instead of relying on temperature changes that are affected by thermal insulation and geometry, the system uses optical fibers to directly detect erosion through light reflection, providing more reliable measurements that are not influenced by thermal conditions.
Solution Approach 2:
The patent introduces optical fibers as an intermediary medium between the erosion surface and the monitoring system. The optical fibers transmit light signals that reflect off the erosion surface, providing a direct optical measurement pathway that bypasses the limitations of thermal monitoring and enables reliable erosion detection regardless of thermal insulation or geometric factors.
3Reliability
If optical fibers are installed inside components to monitor erosion, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent segments the optical fiber installation into discrete, modular units that can be independently installed in different locations. The optical fibers are positioned as separate elements within the component structure, allowing for simplified installation procedures while maintaining reliable erosion monitoring at multiple points.
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
This approach provides a cost-effective and accurate method to monitor erosion in high-temperature environments, enabling early detection of erosion in critical components like valves and cyclones, preventing damage and maintaining plant efficiency.
Implementation Method 1
measure erosion by analyzing light reflections or pulse travel time to determine the depth of erosion
Implementation Method 2
measure erosion by analyzing light reflections or pulse travel time to determine the depth of erosion
Data Source
AI summary
Apparatus for monitoring the erosion of components of industrial plants comprising at least one optical fiber sensor (7′), the optical fibers (7′) not being provided with any Bragg grid, and an analysis unit, wherein the at least one optical fiber sensor (7′) is positioned inside a wall subjected to wear by erosion in such a way as to terminate immediately under the surface of the wall itself belonging to the components (10, 10′, 20, 20′) to be monitored, and the erosion depth is measured by using the light reflected from the eroded end of the optical fiber (7′) itself.