High Temperature Ultrasonic Probe for Steam Pipe Water Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing steam pipe systems face failures due to water condensation leading to water hammer, which can cause damage, and there is a need for real-time monitoring of water height without perforating the pipes, especially at high temperatures.
Innovation Solution
A high-temperature ultrasonic probe system with a piezoelectric transducer and a mounting fixture that allows for blind alignment and operation up to 250°C, using a piezoelectric transducer with a Curie temperature of at least 350°C and a backing to reduce ringing, along with a wireless communication module and digital signal processor, coupled with a mounting fixture that maintains contact and alignment through temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional ultrasonic probes are used in steam pipes, then the monitoring system can detect water condensation, but the probes cannot sustain high temperatures above their Curie point
Solution Approach 1:
The patent changes the material parameter (Curie temperature) of the piezoelectric transducer from conventional values to at least 350°C, enabling the probe to operate reliably in high-temperature steam pipe environments up to 250°C without losing piezoelectric functionality.
Solution Approach 2:
The patent employs composite material construction for the probe housing and mounting fixture, using materials with appropriate thermal expansion coefficients and high-temperature stability to maintain structural integrity and alignment at elevated temperatures.
2Manufacturing precision
If the probe is mounted rigidly to maintain alignment, then alignment precision is improved, but the mounting cannot accommodate thermal expansion and contraction during temperature variations
Solution Approach 1:
The patent replaces rigid mounting with dynamic mounting features including flexures and adjustment mechanisms that allow the probe to maintain precise alignment while accommodating thermal expansion and contraction of the pipe during temperature variations.
Solution Approach 2:
The mounting fixture is designed to compensate for thermal expansion effects, using adjustable components and flexible connections that maintain probe alignment with the pipe axis despite dimensional changes in the pipe due to temperature fluctuations.
3Measurement precision
If the probe element has high sensitivity for detection, then measurement precision is improved, but the probe produces prolonged ringing that reduces measurement resolution
Solution Approach 1:
The patent introduces a backing layer as an intermediary material between the piezoelectric element and the external environment. This backing absorbs and dampens mechanical vibrations, reducing the duration of ringing while preserving the element's sensitivity for detecting water condensation.
4Manufacturing precision
If the mounting fixture is designed for precise alignment, then alignment accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent divides the mounting fixture into modular segments including separate alignment components, mounting brackets, and adjustment mechanisms. This segmentation allows for simplified manufacturing and assembly while maintaining alignment accuracy through standardized interfaces.
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 real-time monitoring of water height in steam pipes without damaging the pipes, effectively preventing water hammer by using a high-temperature ultrasonic probe system that can sustain temperatures up to 250°C and maintain accurate alignment and contact, ensuring reliable operation and safety.
Implementation Method 1
a piezoelectric transducer element having a Curie temperature of at least 350° C. and a mechanical damping (tan δ) of 0.02 or less
Implementation Method 2
electrical output terminals configured to provide a response signal from the piezoelectric transducer element
Implementation Method 3
the backing is configured to reduce the duration of a ringing in the piezoelectric probe element
Data Source
AI summary
A high temperature ultrasonic probe and a mounting fixture for attaching and aligning the probe to a steam pipe using blind alignment. The high temperature ultrasonic probe includes a piezoelectric transducer having a high temperature. The probe provides both transmitting and receiving functionality. The mounting fixture allows the high temperature ultrasonic probe to be accurately aligned to the bottom external surface of the steam pipe so that the presence of liquid water in the steam pipe can be monitored. The mounting fixture with a mounted high temperature ultrasonic probe are used to conduct health monitoring of steam pipes and to track the height of condensed water through the wall in real-time.