Modular Combustion Viewport With Insulated Quartz Panes

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Solution Overview

Problem

Existing viewport designs for high temperature combustion zones, such as those in HRSGs with duct burner elements, face issues like thermally unsafe external surfaces, corrosion, containment failure, small viewing areas, difficulty in installation and maintenance, and a short product life cycle, due to the use of single window panes and internal sliding shielding plates that require manipulation of lever or actuators, posing safety risks.

Innovation Solution

A viewport design featuring two window panes separated by ceramic fiber insulation, eliminating the need for cooling air circulation and internal sliding shielding plates, with a flange for welding to the combustion zone enclosure wall, using 310 stainless steel and quartz glass for enhanced safety and durability, and an enlarged viewing area for improved safety and convenience.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a single window pane with internal sliding shielding plates is used, then observation of burner operation is enabled, but the external surface becomes thermally unsafe and requires manipulation of hot levers or actuators

Engineering Contradiction:

Improveobservation capabilityVSAvoidthermal safety

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The viewport is divided into multiple window panes (first window pane, second window pane) separated by insulation layers, creating distinct thermal zones that isolate the hot combustion area from the external surface, allowing observation without thermal exposure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Ceramic fiber insulation layers are introduced as intermediary materials between the hot combustion zone and the external environment, blocking heat transfer while permitting visual observation through the window panes

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If cooling air ports are added to reduce viewport temperature, then thermal safety is improved, but device complexity and corrosion risk increase

Engineering Contradiction:

Improvethermal safetyVSAvoidviewport structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The harmful function of cooling air ports (which introduce complexity and corrosion) is removed entirely. Instead, passive thermal insulation through ceramic fiber layers and air gaps between panes achieves temperature reduction without additional active components

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If internal sliding shielding plates with levers are used, then burner observation is enabled, but operator safety is compromised due to hot surfaces

Engineering Contradiction:

Improveburner monitoringVSAvoidoperator safety

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Instead of bringing the observer close to the hot zone (single pane with internal shutters), the solution inverts the approach by creating a cold observation surface that faces the hot zone, allowing operators to view burners from a thermally safe position

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of manufacture

If a single window pane is used, then manufacturing is simple, but the viewing area is limited and thermal safety is compromised

Engineering Contradiction:

Improveviewport constructionVSAvoidviewing area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

Multiple window panes are nested within a single viewport housing structure, with each pane contributing to the total viewing area while being thermally isolated from the others through insulation layers

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design provides continuous, safe observation of burner elements with reduced heat transfer risk, increased product life, and improved safety by maintaining a cooler exterior temperature, reducing fatigue and corrosion concerns, and simplifying installation without the need for mechanical shutters.

Implementation Method 1

two window panes separated by ceramic fiber insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11892164B2Viewport for high temperature combustion zones

Publication Date: 2024.02.06 HRST

AI summary

A viewport for a combustion zone includes an inner casing having a flange extending into the combustion zone. A first layer of ceramic fiber insulation is exterior to the inner casing. A middle casing includes two panes of quartz glass separated by traverse plates. A second layer of ceramic fiber insulation is exterior to the middle casing. An outer casing is positioned to the exterior of the second layer of insulation. The middle casing includes L-shaped ledges having third and fourth layers of ceramic insulation. The panes of glass are each positioned between layers of insulation and the insulation positioned in the L-shaped ledges. The viewport is modular enabling the separation of the first layer of insulation, the middle casing, the second layer of insulation and the outer casing from the combustion zone for maintenance or repair. The viewport minimizes heat migration to the outer casing during use.