CN110454766B - Boiler early warning method and early warning device - Google Patents
Boiler early warning method and early warning device Download PDFInfo
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- CN110454766B CN110454766B CN201910585742.8A CN201910585742A CN110454766B CN 110454766 B CN110454766 B CN 110454766B CN 201910585742 A CN201910585742 A CN 201910585742A CN 110454766 B CN110454766 B CN 110454766B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F22—STEAM GENERATION
- F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
- F22B37/00—Component parts or details of steam boilers
- F22B37/02—Component parts or details of steam boilers applicable to more than one kind or type of steam boiler
- F22B37/42—Applications, arrangements, or dispositions of alarm or automatic safety devices
Abstract
The invention discloses a boiler early warning method and an early warning device, wherein the early warning method comprises the steps of obtaining shape data of a boiler drum; acquiring a thermal stress model of the boiler; acquiring a stress field model of the boiler; carrying out finite element simulation on the thermal stress model and the stress field model, and operating the simulation model to obtain simulation parameters of the boiler; acquiring the operation parameters of the boiler at fixed intervals; and comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal. According to the invention, a simulation model closest to the normal operation of the boiler is obtained by a finite element simulation method through a thermal stress model and a stress field model of the boiler, the collected operation parameters of the boiler are compared with the simulation parameters obtained by operating the simulation model, and when the error between the operation parameters and the simulation parameters exceeds the error range, an early warning signal is output, so that the potential hidden danger of the boiler can be early warned, and the fault risk of the boiler is reduced.
Description
Technical Field
The invention relates to the technical field of intelligent detection, in particular to a boiler early warning method and an early warning device thereof.
Background
The boiler is an energy conversion device, the energy input to the boiler comprises chemical energy and electric energy in fuel, and the boiler outputs steam, high-temperature water or an organic heat carrier with certain heat energy. The boiler appears to be a simple industrial plant, but incorrect application can lead to major accidents. The over-pressure operation and the dehydration over-temperature operation of the boiler are easy to cause serious accidents, and the over-pressure operation of the boiler can be caused by the possibility of accidents caused by improper daily maintenance of the boiler, technical failure of boiler operators, rusting of pipelines, cracking of steam drums and the like.
The traditional boiler detection device mainly comprises a pressure gauge, a thermometer, a water level gauge, a safety valve, a control chip and the like, and has the following defects that firstly, if cracks are generated in a pipeline or the wall of a steam drum becomes thin and the like, the pressure value is abnormally changed, but the safety valve does not act due to the tiny changes, and great potential safety hazard exists if the patrol detection of a manager is not timely; secondly, in a traditional boiler safety system, the safety valve is usually operated when the pressure, the temperature or the water level reaches a warning threshold value, the operation method has great hysteresis, and if the safety valve cannot be operated in time due to aging, rusting and the like, great potential safety hazards are generated.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: provided are a boiler safety early warning method and an early warning device based on finite element analysis.
The solution of the invention for solving the technical problem is as follows:
a boiler early warning method comprises the following steps:
step 100, acquiring shape data of a boiler drum;
200, combining shape data of a boiler steam drum, and obtaining a thermal stress model of the boiler according to initial conditions and boundary conditions of the boiler;
step 300, according to a thermal stress model of the boiler, firstly, performing thermal analysis on the thermal stress model of the boiler by adopting a sequential coupling method to obtain a transient temperature field at each moment, and then mapping the node temperature at each moment to a boiler structure to obtain a stress field model of the boiler;
step 400, comparing the obtained thermal stress model and stress field model of the boiler with temperature and pressure parameters in the heating and cooling processes of the boiler under normal operation;
500, modifying boundary conditions of the boiler, repeatedly executing the steps 200 to 400 for a plurality of times, performing finite element simulation on the thermal stress model and the stress field model, taking the thermal stress model and the stress field model which are closest to the real normal operation condition of the boiler as simulation models, and operating the simulation models to obtain simulation parameters of the boiler;
step 600, collecting operating parameters of a boiler at regular intervals;
and 700, setting an error range, comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal if the error between the operation parameters and the simulation parameters exceeds the error range.
As a further improvement of the above technical solution, in step 700, if the error between the operating parameter and the simulation parameter exceeds 10%, an early warning signal is output.
As a further improvement of the above technical solution, in step 200, the shape data of the boiler drum includes the length, width, height, inner diameter, and outer diameter of the boiler drum; solving the heat conduction differential equation of the boiler to obtain a thermal stress model of the boiler, wherein the heat conduction differential equation of the boiler is shown as formula 1:
the boundary conditions include:
adiabatic boundary, as shown in equation 2:
inner wall boundaries, as shown in equation 3:
sandwich convection, as shown in equation 4:
radiation heat exchange, as shown in equation 5:
the initial condition includes an initial temperature of tτ＝0＝t0；
Wherein ρ is the material density; λ is the coefficient of thermal conductivity; r represents the boiler drum radius; c is the specific heat capacity of the material;
to control the volume angle; r is1Is the inner diameter of a boiler steam drum; r is2Is the outer diameter of a boiler drum; q is the heat flow density in w/m2；hjIs the convection heat transfer coefficient at the outer wall of the interlayer and has the unit of w/(m)2·k)；hwThe heat transfer coefficient of convection between the inner wall of the boiler barrel and saturated water is expressed in unit of w/(m)2·k)；hsRepresents the convective heat transfer coefficient of saturated water vapor with the unit of w/(m)2·k)；tfThe temperature of the fluid on the outer wall of the interlayer is measured in centigrade degrees; τ is time in seconds; t represents time; t is t0Is the initial temperature in degrees celsius; t is t∞Is the saturation temperature of the fluid in degrees celsius.
As a further improvement of the above technical solution, in step 300, after the transient temperature field at each time is obtained, the node temperature at each time is mapped into the boiler structure, thermal stress is generated by using the node temperature as a known external load in combination with the material structure characteristics of the boiler, and a stress field model of the boiler is established in combination with the calculated thermal stress data corresponding to the node temperatures in different transient temperature fields and the data of the corresponding transient temperature fields.
As a further improvement of the above technical solution, after step 600, step 700 is further included, which is to generate a numerical curve corresponding to each operating parameter according to the operating parameters of the boiler, calculate an increasing trend of each numerical curve, determine whether the increasing trend of each numerical curve is abnormal, and if so, output an early warning signal.
The invention also discloses a boiler early warning device, which comprises:
the input module is used for inputting shape data of the boiler steam drum;
the thermal stress model generation module is used for combining the shape data of the boiler steam drum and obtaining a thermal stress model of the boiler according to the initial condition and the boundary condition of the boiler;
the stress field model generation module is used for firstly carrying out thermal analysis on the thermal stress model of the boiler by adopting a sequential coupling method according to the thermal stress model of the boiler to obtain a transient temperature field at each moment, and then mapping the node temperature at each moment to the boiler structure to obtain a stress field model of the boiler;
the comparison module is used for comparing the obtained thermal stress model and the stress field model of the boiler with the temperature and pressure parameters of the boiler in the heating and cooling processes under normal operation;
the simulation model generation module is used for modifying boundary conditions of the boiler, carrying out finite element simulation on the thermal stress model and the stress field model, taking the thermal stress model and the stress field model which are closest to the boiler under the real normal operation condition as simulation models, and operating the simulation models to obtain simulation parameters of the boiler;
the sensor module is used for acquiring the operation parameters of the boiler and performing wireless data uploading operation on the operation parameters;
and the first early warning module is used for setting an error range, comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal if the error between the operation parameters and the simulation parameters exceeds the error range.
As a further improvement of the above technical solution, the boiler early warning device further includes:
the trend calculation module is used for generating a numerical curve corresponding to each operation parameter according to the operation parameters of the boiler and calculating the increasing trend of each numerical curve;
and the second early warning module is used for judging whether the increasing trend of each numerical curve is abnormal or not, and if so, outputting an early warning signal.
The invention has the beneficial effects that: according to the invention, a simulation model closest to the normal operation of the boiler is obtained by a finite element simulation method through a thermal stress model and a stress field model of the boiler, the collected operation parameters of the boiler are compared with the simulation parameters obtained by operating the simulation model, and when the error between the operation parameters and the simulation parameters exceeds the error range, an early warning signal is output, so that the potential hidden danger of the boiler can be early warned, and the fault risk of the boiler is reduced.
Drawings
In order to more clearly illustrate the technical solution in the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly described below. It is clear that the described figures are only some embodiments of the invention, not all embodiments, and that a person skilled in the art can also derive other designs and figures from them without inventive effort.
FIG. 1 is a flow chart of the method of the present invention.
Detailed Description
The conception, the specific structure and the technical effects of the present invention will be clearly and completely described below in conjunction with the embodiments and the accompanying drawings to fully understand the objects, the features and the effects of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present application, and not all embodiments, and other embodiments obtained by those skilled in the art without inventive efforts based on the embodiments of the present application belong to the protection scope of the present application. In addition, all the connection relations mentioned herein do not mean that the components are directly connected, but mean that a better connection structure can be formed by adding or reducing connection accessories according to the specific implementation situation. All technical characteristics in the invention can be interactively combined on the premise of not conflicting with each other. Finally, it should be noted that the terms "center, upper, lower, left, right, vertical, horizontal, inner, outer" and the like as used herein refer to an orientation or positional relationship based on the drawings, which is only for convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present application.
Referring to fig. 1, the present application discloses a boiler early warning method, a first embodiment of which includes the steps of:
a boiler early warning method comprises the following steps:
step 100, acquiring shape data of a boiler drum;
200, combining shape data of a boiler steam drum, and obtaining a thermal stress model of the boiler according to initial conditions and boundary conditions of the boiler;
step 300, according to a thermal stress model of the boiler, firstly, performing thermal analysis on the thermal stress model of the boiler by adopting a sequential coupling method to obtain a transient temperature field at each moment, and then mapping the node temperature at each moment to a boiler structure to obtain a stress field model of the boiler;
step 400, comparing the obtained thermal stress model and stress field model of the boiler with temperature and pressure parameters in the heating and cooling processes of the boiler under normal operation;
500, modifying boundary conditions of the boiler, repeatedly executing the steps 200 to 400 for a plurality of times, performing finite element simulation on the thermal stress model and the stress field model, taking the thermal stress model and the stress field model which are closest to the real normal operation condition of the boiler as simulation models, and operating the simulation models to obtain simulation parameters of the boiler;
step 600, collecting operating parameters of a boiler at regular intervals;
and 700, setting an error range, comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal if the error between the operation parameters and the simulation parameters exceeds the error range.
Specifically, in this embodiment, a simulation model closest to the normal operation of the boiler is obtained by using a finite element simulation method through a thermal stress model and a stress field model of the boiler, the collected operating parameters of the boiler are compared with the simulation parameters obtained by operating the simulation model, and when the error between the operating parameters and the simulation parameters exceeds an error range, an early warning signal is output, so that the potential hidden danger of the boiler can be early warned, and the fault risk of the boiler is reduced.
Further as a preferred implementation manner, in this embodiment, in step 700, if an error between the operating parameter and the simulation parameter exceeds 10%, an early warning signal is output.
Further as a preferred implementation manner, in the present embodiment, in the step 200, the shape data of the boiler drum includes a length, a width, a height, an inner diameter, and an outer diameter of the boiler drum; solving the heat conduction differential equation of the boiler to obtain a thermal stress model of the boiler, wherein the heat conduction differential equation of the boiler is shown as formula 1:
the boundary conditions include:
adiabatic boundary, as shown in equation 2:
inner wall boundaries, as shown in equation 3:
sandwich convection, as shown in equation 4:
radiation heat exchange, as shown in equation 5:
the initial condition includes an initial temperature of tτ＝0＝t0；
Wherein ρ is the material density; λ is a heat conduction systemCounting; r represents the boiler drum radius; c is the specific heat capacity of the material;
to control the volume angle; r is1Is the inner diameter of a boiler steam drum; r is2Is the outer diameter of a boiler drum; q is the heat flow density in w/m2；hjIs the convection heat transfer coefficient at the outer wall of the interlayer and has the unit of w/(m)2·k)；hwThe heat transfer coefficient of convection between the inner wall of the boiler barrel and saturated water is expressed in unit of w/(m)2·k)；hsRepresents the convective heat transfer coefficient of saturated water vapor with the unit of w/(m)2·k)；tfThe temperature of the fluid on the outer wall of the interlayer is measured in centigrade degrees; τ is time in seconds; t represents time; t is t0Is the initial temperature in degrees celsius; t is t∞Is the saturation temperature of the fluid in degrees celsius.
Further as a preferred implementation manner, in the present embodiment, in the step 300, after the transient temperature field at each time is obtained, the node temperature at each time is mapped into the boiler structure, the thermal stress is generated by using the node temperature as a known external load in combination with the material structure characteristics of the boiler, and the stress field model of the boiler is established in combination with the calculated thermal stress data corresponding to the node temperatures of different transient temperature fields and the data of the corresponding transient temperature fields. The calculation formula of the thermal stress is shown as formula 6:
th＝α(θ)(θ-θ°)-α(θI)(θI- θ °) formula 6
Where alpha is the thermal expansion coefficient of the boiler, theta is the reference temperature, thetaIIs the initial temperature.
Further as a preferred implementation manner, in this embodiment, after the step 600, a step 700 is further included, in which a numerical curve corresponding to each operating parameter is generated according to the operating parameter of the boiler, an increasing trend of each numerical curve is calculated, whether the increasing trend of each numerical curve is abnormal is determined, and if yes, an early warning signal is output. Specifically, this embodiment disposes the detection function of boiler operation parameter growth trend, if the operation parameter of boiler produces unusual change in the short time, can explain that the boiler has produced corresponding trouble, needs output early warning signal in order to remind relevant staff to notice.
The application also discloses a boiler early warning device simultaneously, its first embodiment includes:
the input module is used for inputting shape data of the boiler steam drum;
the thermal stress model generation module is used for combining the shape data of the boiler steam drum and obtaining a thermal stress model of the boiler according to the initial condition and the boundary condition of the boiler;
the stress field model generation module is used for firstly carrying out thermal analysis on the thermal stress model of the boiler by adopting a sequential coupling method according to the thermal stress model of the boiler to obtain a transient temperature field at each moment, and then mapping the node temperature at each moment to the boiler structure to obtain a stress field model of the boiler;
the comparison module is used for comparing the obtained thermal stress model and the stress field model of the boiler with the temperature and pressure parameters of the boiler in the heating and cooling processes under normal operation;
the simulation model generation module is used for modifying boundary conditions of the boiler, carrying out finite element simulation on the thermal stress model and the stress field model, taking the thermal stress model and the stress field model which are closest to the boiler under the real normal operation condition as simulation models, and operating the simulation models to obtain simulation parameters of the boiler;
the sensor module is used for acquiring the operation parameters of the boiler and performing wireless data uploading operation on the operation parameters;
and the first early warning module is used for setting an error range, comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal if the error between the operation parameters and the simulation parameters exceeds the error range.
Further as a preferred implementation manner, in this embodiment, the boiler early warning device further includes:
the trend calculation module is used for generating a numerical curve corresponding to each operation parameter according to the operation parameters of the boiler and calculating the increasing trend of each numerical curve;
and the second early warning module is used for judging whether the increasing trend of each numerical curve is abnormal or not, and if so, outputting an early warning signal.
While the preferred embodiments of the present invention have been described in detail, it should be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
Claims (7)
1. A boiler early warning method is characterized by comprising the following steps:
step 100, acquiring shape data of a boiler drum;
200, combining shape data of a boiler steam drum, and obtaining a thermal stress model of the boiler according to initial conditions and boundary conditions of the boiler;
step 300, according to a thermal stress model of the boiler, firstly, performing thermal analysis on the thermal stress model of the boiler by adopting a sequential coupling method to obtain a transient temperature field at each moment, and then mapping the node temperature at each moment to a boiler structure to obtain a stress field model of the boiler;
step 400, comparing the obtained temperature and pressure parameters of the thermal stress model and the stress field model of the boiler with the temperature and pressure parameters of the heating and cooling processes of the boiler under normal operation;
500, modifying boundary conditions of the boiler, repeatedly executing the steps 200 to 400 for a plurality of times, performing finite element simulation on the thermal stress model and the stress field model, taking the thermal stress model and the stress field model which are closest to the real normal operation condition of the boiler as simulation models, and operating the simulation models to obtain simulation parameters of the boiler;
step 600, collecting operating parameters of a boiler at regular intervals;
and 700, setting an error range, comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal if the error between the operation parameters and the simulation parameters exceeds the error range.
2. The boiler early warning method according to claim 1, wherein: in step 700, if the error between the operation parameter and the simulation parameter exceeds 10%, an early warning signal is output.
3. The boiler early warning method according to claim 1, wherein: in step 200, the shape data of the boiler drum comprises the length, width, height, inner diameter, and outer diameter of the boiler drum; solving the heat conduction differential equation of the boiler to obtain a thermal stress model of the boiler, wherein the heat conduction differential equation of the boiler is shown as formula 1:
the boundary conditions include:
adiabatic boundary, as shown in equation 2:
inner wall boundaries, as shown in equation 3:
sandwich convection, as shown in equation 4:
radiation heat exchange, as shown in equation 5:
the initial condition includes an initial temperature of tτ＝0＝t0；
Wherein ρ is the material density; λ is the coefficient of thermal conductivity; r represents the boiler drum radius; c is the specific heat capacity of the material;
to control the volume angle; r is1Is the inner diameter of a boiler steam drum; r is2Is the outer diameter of a boiler drum; q is the heat flow density in w/m2；hjIs the convection heat transfer coefficient at the outer wall of the interlayer and has the unit of w/(m)2·k)；hwThe heat transfer coefficient of convection between the inner wall of the boiler barrel and saturated water is expressed in unit of w/(m)2·k)；hsRepresents the convective heat transfer coefficient of saturated water vapor with the unit of w/(m)2·k)；tfThe temperature of the fluid on the outer wall of the interlayer is measured in centigrade degrees; τ is time in seconds; t represents time; t is t0Is the initial temperature in degrees celsius; t is t∞Is the saturation temperature of the fluid in degrees celsius.
4. The boiler early warning method according to claim 1, wherein: in step 300, after the transient temperature fields at each moment are obtained, the node temperatures at each moment are mapped into a boiler structure, thermal stress is generated by taking the node temperatures as known external loads according to the material structure characteristics of the boiler, and a stress field model of the boiler is established according to the calculated thermal stress data corresponding to the node temperatures of different transient temperature fields and the data of the corresponding transient temperature fields.
5. The boiler early warning method according to claim 1, wherein: after step 600, step 700 is further included, a numerical curve corresponding to each operation parameter is generated according to the operation parameters of the boiler, the growth trend of each numerical curve is calculated, whether the growth trend of each numerical curve is abnormal or not is judged, and if yes, an early warning signal is output.
6. A boiler early warning device, its characterized in that includes:
the input module is used for inputting shape data of the boiler steam drum;
the thermal stress model generation module is used for combining the shape data of the boiler steam drum and obtaining a thermal stress model of the boiler according to the initial condition and the boundary condition of the boiler;
the stress field model generation module is used for firstly carrying out thermal analysis on the thermal stress model of the boiler by adopting a sequential coupling method according to the thermal stress model of the boiler to obtain a transient temperature field at each moment, and then mapping the node temperature at each moment to the boiler structure to obtain a stress field model of the boiler;
the comparison module is used for comparing the obtained temperature and pressure parameters of the thermal stress model and the stress field model of the boiler with the temperature and pressure parameters of the heating and cooling processes of the boiler under normal operation;
the simulation model generation module is used for modifying boundary conditions of the boiler, carrying out finite element simulation on the thermal stress model and the stress field model, taking the thermal stress model and the stress field model which are closest to the boiler under the real normal operation condition as simulation models, and operating the simulation models to obtain simulation parameters of the boiler;
the sensor module is used for acquiring the operation parameters of the boiler and performing wireless data uploading operation on the operation parameters;
and the first early warning module is used for setting an error range, comparing the collected operation parameters of the boiler with the simulation parameters obtained by operating the simulation model, and outputting an early warning signal if the error between the operation parameters and the simulation parameters exceeds the error range.
7. The boiler early warning device according to claim 6, further comprising:
the trend calculation module is used for generating a numerical curve corresponding to each operation parameter according to the operation parameters of the boiler and calculating the increasing trend of each numerical curve;
and the second early warning module is used for judging whether the increasing trend of each numerical curve is abnormal or not, and if so, outputting an early warning signal.
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