CN111256102A - Boiler expansion monitoring method and system - Google Patents
Boiler expansion monitoring method and system Download PDFInfo
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- CN111256102A CN111256102A CN202010219203.5A CN202010219203A CN111256102A CN 111256102 A CN111256102 A CN 111256102A CN 202010219203 A CN202010219203 A CN 202010219203A CN 111256102 A CN111256102 A CN 111256102A
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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
- F22B37/428—Feed-water supply alarm devices using dilatation of solids or liquids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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Abstract
The invention discloses a boiler expansion monitoring method and a boiler expansion monitoring system, wherein the method comprises the following steps: selecting an expansion dead point and a plurality of expansion measuring points on a boiler, and establishing a three-dimensional coordinate system by taking the expansion dead point as an original point; acquiring real-time expansion data of each expansion measurement point; calculating real-time expansion data of each target expansion point on the boiler; determining the theoretical expansion amount of the expansion measuring point; calculating the theoretical expansion amount of each target expansion point on the boiler according to the theoretical expansion amount of the corresponding expansion measurement point; and judging whether the running state of each target expansion point on the boiler is normal or not according to the real-time expansion data of each target expansion point and the calculated theoretical expansion amount. The method provided by the invention can not only detect the expansion condition of the expansion measuring point, but also analyze the expansion condition of any position of the boiler, thereby realizing the guidance of the boiler system operation and the analysis of the service life of the metal material, and being more comprehensive and accurate.
Description
Technical Field
The invention relates to the field of expansion monitoring, in particular to a boiler expansion monitoring method and system.
Background
Currently, boiler expansion monitoring still mainly records data of a mechanical expansion device, and computer remote monitoring in the true sense is not realized. The reason is that there are several aspects:
one is that the measurement problem is not solved at all. At present, the multi-dimensional measurement scheme for boiler expansion is more, but most of the measurement schemes are simple in principle, inconvenient to install and implement, high in cost and difficult to popularize.
And secondly, the load of the boiler of the conventional power plant is relatively stable, so that the expansion times and the expansion amplitude of the boiler are relatively small, and the monitoring and analysis urgency on the expansion of the boiler is not high. However, with the change of the grid structure, the load of the boiler of the thermal power plant frequently changes from 30% to 100%, and even the boiler needs to be frequently started and stopped, so that the frequency and the amplitude of expansion of the boiler are greatly increased. Under the condition, continuous monitoring and analysis on boiler expansion of the power plant are urgently needed, the operation condition of the boiler is mastered, and the service life and the health condition of metal are analyzed, so that data support is provided for optimizing the overhauling frequency of the boiler and key inspection positions.
Thirdly, the number of expansion measuring points of the large boiler is large, so that the number of data acquisition points is large, more cables and I/O (input/output) clamping pieces are required to be consumed, and the cost cannot be effectively reduced.
Therefore, how to effectively improve the accuracy and efficiency of the inflation monitoring is a technical problem that needs to be solved by those skilled in the art.
Disclosure of Invention
The invention aims to provide a boiler expansion monitoring method and a boiler expansion monitoring system, which are used for acquiring and analyzing the expansion amount of each expansion measuring point and providing more accurate guidance and service life analysis for the operation of a boiler.
In order to achieve the purpose, the invention provides the following technical scheme:
a boiler expansion monitoring method comprising the steps of:
selecting an expansion dead point and a plurality of expansion measuring points on the boiler, and establishing a three-dimensional coordinate system by taking the expansion dead point as an origin;
acquiring real-time expansion data of each expansion measuring point;
calculating real-time expansion data of each target expansion point on the boiler according to the corresponding real-time expansion data of the expansion measurement points;
acquiring pressure, temperature and variation thereof at each expansion measuring point, and determining theoretical expansion amount of the expansion measuring points;
calculating the theoretical expansion amount of each target expansion point on the boiler according to the corresponding theoretical expansion amount of the expansion measurement point;
and judging whether the running state of each target expansion point on the boiler is normal or not according to the real-time expansion data of each target expansion point and the calculated theoretical expansion amount.
Preferably, the calculating real-time expansion data of each target expansion point on the boiler according to the real-time expansion data of each expansion measurement point includes:
determining the coordinate of a target expansion point to be calculated before expansion;
selecting coordinates of a corresponding reference expansion measuring point before expansion and real-time expansion data of the reference expansion measuring point;
performing equal proportion calculation according to the position relationship between the target expansion point and the expansion dead point before expansion, the position relationship between the reference expansion measurement point and the expansion dead point before expansion and the position relationship between the reference expansion measurement point and the expansion dead point after expansion to obtain real-time expansion data of the target expansion point;
the calculating the theoretical expansion amount of each target expansion point on the boiler according to the corresponding theoretical expansion amount of the expansion measurement point comprises the following steps:
determining the coordinate of a target expansion point to be calculated before expansion;
selecting coordinates of a corresponding reference expansion measuring point before expansion and theoretical expansion data of the reference expansion measuring point;
performing equal proportion calculation according to the position relation between the target expansion point and the expansion dead point before expansion, the position relation between the reference expansion measurement point and the expansion dead point before expansion and the position relation between the reference expansion measurement point and the expansion dead point after expansion to obtain theoretical expansion data of the target expansion point;
the reference expansion measurement point is the closest expansion measurement point ahead of the target expansion point with respect to the expansion direction of the expansion dead point;
the reference expansion measurement point is a closest expansion measurement point ahead of the target expansion point with respect to an expansion direction of the expansion dead point.
It is preferable thatSetting the coordinate of the reference expansion measuring point before expansion as x0，y0，z0(ii) a Coordinate x of the target expansion point before expansion01，y01，z01(ii) a When the real-time expansion amount monitored by the expansion measuring point is delta x0、Δy0、Δz0Then x01，y01，z01The expansion values of (a) are:
Δx01＝(x01/x0)*Δx0；
Δy01＝(y01/y0)*Δy0；
Δz01＝(z01/z0)*Δz0。
preferably, the method further comprises the following steps:
setting a measurement period, and acquiring real-time expansion data of each expansion measurement point in each measurement period;
and acquiring a dynamic three-dimensional image when the boiler expands according to the original shape and the original size of the boiler and the real-time expansion data of each expansion point.
Preferably, the method further comprises the following steps:
and when the real-time expansion data of each target expansion point on the boiler is smaller than the preset allowable range of the theoretical expansion amount, sending an expansion blocking alarm signal.
Preferably, the method further comprises the following steps:
selecting a plurality of target expansion points as the same group of target expansion points according to the shape of the boiler;
and when the difference between the real-time expansion data of one target expansion point in the same group of target expansion points and the real-time expansion data of any other target expansion points in the same group is 5% -10%, sending out an uneven expansion alarm signal.
Preferably, the method further comprises the following steps:
determining a nominal expansion rate from the temperature and pressure at the expansion measurement point;
and when the expansion rate of each target expansion point on the boiler is greater than the rated expansion rate, sending an expansion rate alarm signal.
Preferably, the expansion rate of each target expansion point on the boiler comprises:
the rate of outward expansion of each target expansion point when the boiler is heated and/or the rate of contraction of each target expansion point when the boiler is cooled.
Preferably, the method further comprises the following steps:
counting the boiler fatigue degree, and when the boiler metal fatigue value (N +1) of a region represented by a certain expansion measuring point is greater than a preset fatigue value, maintaining the metal pipe in the region;
boiler metal fatigue score (N +1) ═ boiler metal fatigue score (N) + boiler expansion score pulse coefficient 1+ boiler expansion rate pulse coefficient 2;
wherein, the metal fatigue score (N +1) of the boiler is the latest metal fatigue score of the boiler, and the metal fatigue score (N) of the boiler is the metal fatigue score of the last boiler; the boiler expansion counting pulse is 1 or 0, when the expansion amount of the expansion measuring point is greater than the rated expansion amount or the contraction amount is less than the preset contraction amount, counting is carried out, the boiler expansion counting pulse sends a pulse, the pulse is changed from 0 to 1, and then recovery is carried out; the boiler expansion rate pulse is 1 or 0, when the expansion rate of the expansion measuring point exceeds a preset expansion rate, the boiler expansion rate pulse is changed from 0 to 1, and then the boiler expansion rate pulse is recovered; the coefficients 1 and 2 are empirical values.
A boiler expansion monitoring system comprises an expansion monitoring device, a controller, an expansion monitoring instrument and a server, wherein the expansion monitoring instrument is used for displaying real-time expansion data of each expansion measuring point, the server is used for executing image display or executing alarm, and the controller is used for executing the boiler expansion monitoring method.
The boiler expansion monitoring method provided by the invention comprises the following steps: selecting an expansion dead point and a plurality of expansion measuring points on the boiler, and establishing a three-dimensional coordinate system by taking the expansion dead point as an origin; acquiring real-time expansion data of each expansion measuring point; calculating real-time expansion data of each target expansion point on the boiler according to the corresponding real-time expansion data of the expansion measurement points; acquiring pressure, temperature and variation thereof at each expansion measuring point, and determining theoretical expansion amount of the expansion measuring points; calculating the theoretical expansion amount of each target expansion point on the boiler according to the corresponding theoretical expansion amount of the expansion measurement point; and judging whether the running state of each target expansion point on the boiler is normal or not according to the real-time expansion data of each target expansion point and the calculated theoretical expansion amount. The boiler expansion monitoring method provided by the invention can calculate the real-time expansion data of each target expansion point after collecting the real-time expansion data of each expansion measurement point of the boiler through the establishment of a coordinate system, and then analyzes whether the running state of the boiler is normal or not through the comparison of the real-time expansion data of each target expansion point and a theoretical expansion value.
The boiler expansion monitoring system provided by the invention comprises a controller, an expansion monitoring instrument and a server, wherein the expansion monitoring instrument is used for displaying real-time expansion data of each expansion measuring point, the server is used for executing image display or executing alarm, and the controller is used for executing the boiler expansion monitoring method. Due to the technical effects of the boiler expansion monitoring method, the boiler expansion monitoring system also has corresponding technical effects.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a flow chart of a boiler expansion monitoring method provided by the present invention;
FIG. 2 is a schematic diagram illustrating the establishment of a coordinate system in the boiler expansion monitoring method according to the present invention;
FIG. 3 is a schematic diagram of a boiler expansion monitoring system provided by the present invention;
FIG. 4 is a schematic structural diagram of an expansion monitoring device in the boiler expansion monitoring system provided by the present invention;
wherein: the device comprises a detection assembly-100, a main body frame-101, a probe bracket-102, a frame fixing rod-103, a first connecting piece-104 and a second connecting piece-105; a variable assembly-200, a displacement variable block-201 and a variable block fixing rod-202; server-400, controller-500.
Detailed Description
The core of the invention is to provide a boiler expansion monitoring method and a boiler expansion monitoring system, which are used for acquiring and analyzing the expansion amount of each expansion measuring point and providing more accurate guidance and service life analysis for the operation of the boiler.
In order that those skilled in the art will better understand the disclosure, the invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Referring to fig. 1 to 4, fig. 1 is a flow chart illustrating a boiler expansion monitoring method according to the present invention; FIG. 2 is a schematic diagram illustrating the establishment of a coordinate system in the boiler expansion monitoring method according to the present invention; FIG. 3 is a schematic diagram of a boiler expansion monitoring system provided by the present invention; fig. 4 is a schematic structural diagram of an expansion monitoring device in the boiler expansion monitoring system provided by the invention.
In this embodiment, the boiler expansion monitoring method comprises the steps of:
step S1: selecting an expansion dead point and a plurality of expansion measuring points on the boiler, and establishing a three-dimensional coordinate system by taking the expansion dead point as an original point, wherein the expansion dead point is a point A as shown in figure 2; specifically, each expansion measuring point is provided with a measuring device;
step S2: acquiring real-time expansion data of each expansion measurement point through a measurement device;
step S3: calculating real-time expansion data of each target expansion point on the boiler according to the real-time expansion data of the corresponding expansion measurement point; wherein, the target expansion point can be any point on the boiler;
step S4: acquiring pressure, temperature and variable quantity thereof at each expansion measuring point, and determining theoretical expansion quantity of the expansion measuring points;
step S5: calculating the theoretical expansion amount of each target expansion point on the boiler according to the theoretical expansion amount of the corresponding expansion measurement point; the calculation method of the theoretical expansion value of the target expansion point may be the same as the calculation direction of the real-time expansion data.
Step S6: judging whether the running state of each target expansion point on the boiler is normal or not according to the real-time expansion data of each target expansion point and the calculated theoretical expansion amount; specifically, the comparison of the expansion data preferably includes X, Y, Z vector comparisons in the directions of three coordinate axes, and a vector comparison obtained by summing the three vectors, and when any one of the vectors is abnormal, an alarm signal should be sent.
The boiler expansion monitoring method provided by the invention can calculate the real-time expansion data of each target expansion point after collecting the real-time expansion data of each expansion measurement point of the boiler through the establishment of the coordinate system, and then analyzes whether the running state of the boiler is normal or not through the comparison of the real-time expansion data of each target expansion point and a theoretical expansion value.
In addition to the above embodiments, calculating real-time expansion data for each target expansion point on the boiler from the real-time expansion data for each expansion measurement point comprises:
determining the coordinate of a target expansion point to be calculated before expansion;
selecting the coordinates of the corresponding reference expansion measuring points before expansion and real-time expansion data of the reference expansion measuring points;
according to the position relation between the target expansion point before expansion and the expansion dead point, the position relation between the reference expansion measurement point before expansion and the expansion dead point and the position relation between the reference expansion measurement point after expansion and the expansion dead point, carrying out equal proportion calculation to obtain real-time expansion data of the target expansion point;
the reference expansion measurement point is the expansion measurement point closest in front of the target expansion point with respect to the expansion direction of the expansion dead point.
Specifically, the coordinate of a reference expansion measuring point before expansion is set as x0，y0，z0(ii) a Coordinate x of target expansion point before expansion01，y01，z01(ii) a When the real-time expansion amount monitored by the expansion measuring point is delta x0、Δy0、Δz0When (Δ x)0、Δy0、Δz0Either positive or negative), then x01，y01，z01The expansion values of (a) are:
Δx01＝(x01/x0)*Δx0；
Δy01＝(y01/y0)*Δy0；
Δz01＝(z01/z0)*Δz0。
similarly, calculating the theoretical expansion amount of each target expansion point on the boiler according to the theoretical expansion amount of the corresponding expansion measurement point comprises:
determining the coordinate of a target expansion point to be calculated before expansion;
selecting the coordinates of the corresponding reference expansion measuring points before expansion and theoretical expansion data of the reference expansion measuring points;
performing equal proportion calculation according to the position relation between the target expansion point before expansion and the expansion dead point, the position relation between the reference expansion measurement point before expansion and the expansion dead point, and the position relation between the reference expansion measurement point after expansion and the expansion dead point to obtain theoretical expansion data of the target expansion point;
the reference expansion measurement point is the closest expansion measurement point ahead of the target expansion point with respect to the expansion direction of the expansion dead point;
the reference expansion measurement point is the expansion measurement point closest in front of the target expansion point with respect to the expansion direction of the expansion dead point. The specific calculation method may refer to the calculation method of the real-time expansion data.
In addition to the above embodiments, the present invention further includes:
setting a measurement period, and acquiring real-time expansion data of each expansion measurement point in each measurement period;
and acquiring a dynamic three-dimensional image when the boiler expands according to the original shape and the original size of the boiler and the real-time expansion data of each expansion point.
In the method provided by the embodiment, the boiler picture is displayed as a three-dimensional picture, and the expansion amount of any boiler position can be checked through a mouse or a keyboard in a turnover mode. Wherein, the three-dimensional picture of the boiler can be obtained by scaling down according to the design drawing of the boiler.
Specifically, because the height of a large-scale generator set boiler reaches about 100 meters, the structure is very complicated, and when boiler expansion measuring points are arranged, about 40 boiler expansion measuring points are arranged, and all parts of the boiler cannot be covered. In order to obtain the expansion values of all positions, the method provided by the embodiment is adopted, and specifically: firstly, the expansion dead point when the boiler is designed is preferably at the top of the boiler; the boiler is suspended in the air, an expansion dead point is a point where the position of the boiler is unchanged when the boiler expands, and other parts of the boiler expand outwards by taking the expansion dead point as a center, so that the top of the boiler is set as a boiler expansion calculation zero point, the boiler expansion is divided into three directions by taking the point as the center, the downward direction is set as the z direction, the boiler can only expand downwards and cannot expand upwards, the boiler can be arranged forwards, the direction of the front wall of the boiler can be set as the positive direction of the x direction, the reverse direction is the negative direction, the boiler can be arranged leftwards, and the direction of the left wall of the boiler can be set as the positive direction. These directions are chosen to coincide with the measurement directions of the expansion measuring device installed in situ, so that numerically calculated coordinates are obtained. That is, the boiler is divided into four vector sections, as shown in FIG. 2.
Further, the expansion amounts of the respective target expansion points are calculated one by one from a position closest to the boiler expansion dead point toward a direction away from the boiler expansion dead point. The target expansion measurement point selected in the calculation is the data of the expansion amount measurement point closest to the point in the expansion direction of the point, that is, forward in the expansion direction of the target expansion point. The x, y, and z expansion amounts of the target expansion measurement point are calculated in equal proportion by the x, y, and z distances from the expansion dead point of the target expansion measurement point. Because the boiler expansion measuring points are arranged in sections according to the boiler structure, and the boiler expansion measured by each expansion measuring point is a comprehensive expansion integrating all the metal characteristics between the two expansion measuring points, the expansion of each point can be basically represented by adopting equal proportion calculation.
Furthermore, when the boiler operates, all parts of the boiler expand, and the expansion amount of all the parts of the boiler can be calculated through the method, namely the expansion amount of any target expansion point can be calculated. At the moment, the expansion amount of each point can be obtained through calculation, the original three-dimensional picture of the boiler is corrected, and when the mouse stops at a certain part of the picture, the expansion amount of the part can be automatically displayed. Meanwhile, according to a preset period, according to the expansion data of each expansion measuring point, the expansion quantity parameters of each target expansion point of the boiler picture are calculated once and stored as historical data. The historical data can be used as a data source for dynamically displaying the expansion process of the boiler, can also be used as a data source for calculating the expansion stress of the boiler, and can also be used as a data source for fault analysis.
When the dynamic display of the expansion process is carried out, the software calls the boiler expansion data in a selected time period, calls the expansion data of each target expansion point at each time point one by one according to a set period, and corrects the position parameters of each point of the boiler for display, thereby forming a dynamic picture along with the change of time and reflecting the expansion process of the boiler.
In addition to the above embodiments, the present invention further includes:
and when the real-time expansion data of each target expansion point on the boiler is smaller than the preset allowable range of the theoretical expansion amount, sending an expansion blocking alarm signal.
Specifically, the theoretical expansion amounts of the boiler at different temperatures are calculated according to a formula Δ L — L × α × Δ T (L is an initial length, α is a linear expansion coefficient, Δ T temperature variation, and Δ L is a length variation, that is, a linear expansion amount), and the theoretical expansion amounts of the boiler at different temperatures at each point are calculated.
ΔLx0＝x0*α*ΔT
ΔLy0＝y0*α*ΔT
ΔLz0＝z0*α*ΔT
x0，y0，z0To measure the coordinate of the point before expansion, Δ T is the difference between the current temperature of the boiler and the selected reference temperature before expansion. Of course, according to the structure of the boiler and the material of different parts, different linear expansion coefficients can be adopted when the expansion amount of different positions of the boiler is calculated. Specifically, the theoretical expansion amount calculation method may refer to the prior art.
In addition to the above embodiments, the present invention further includes:
selecting a plurality of target expansion points as a same group of target expansion points according to the shape of the boiler, wherein the same group of target expansion points can be a plurality of points under a certain parameter specification, for example, each point with the same Z coordinate is used as the same group of target expansion points;
and when the difference between the real-time expansion data of one target expansion point in the same group of target expansion points and the real-time expansion data of any other target expansion points in the same group is 5% -10%, an alarm signal for uneven expansion is sent out.
In addition to the above embodiments, the present invention further includes:
determining a nominal expansion rate from the temperature and pressure at the expansion measurement point;
and when the expansion rate of each target expansion point on the boiler is greater than the rated expansion rate, sending an expansion rate alarm signal.
Specifically, the boiler expansion rate refers to the amount of expansion of the boiler per unit time. In the method provided in this embodiment, the measurement of the expansion rate is implemented by:
let the coordinates of the inflated measurement point before inflation be x, y, z, at the initial instant, i.e. att0The amount of expansion at that time is Δ x (t)0)，Δy(t0)，Δz(t0) After a unit of time, i.e. t1The amount of expansion at that time is Δ x (t)1)，Δy(t1)，Δz(t1) Then its boiler expansion rate per unit time VL＝sqrt{[Δx(t1)-Δx(t0)]2+[Δy(t1)-Δy(t0)]2+[Δz(t1)-Δz(t0)]2}. Specifically, the rated expansion rate calculation method can refer to the prior art.
In addition to the above embodiments, the expansion rate of each target expansion point on the boiler comprises:
the rate at which each target expansion point expands outward as the boiler heats up and/or the rate at which each target expansion point contracts as the boiler cools down.
Further, the alarm of the boiler expansion amount is divided into two conditions:
the first is an inflation obstruction alarm. Specifically, when the temperature of the medium inside the boiler changes, the boiler should expand according to the temperature of the medium. If the boiler expansion measurement point monitors that the boiler is not expanded or the expansion amount is smaller than the theoretical expansion amount or the designed expansion amount or the empirical expansion amount after the temperature of the medium in the boiler is changed, and the preset alarm value is reached, preferably, the deviation alarm amount is selected according to 5% -15% of the theoretical expansion amount, and then an expansion blocking alarm is sent out;
the second is the alarm of uneven expansion of the boiler. Specifically, when the expansion amount of a certain target expansion point in the same group of target expansion points is monitored to have obvious deviation, and the difference is preferably 5% -10% with the real-time expansion data of any other target expansion point in the same group, an alarm of uneven expansion of the boiler is given out. The uneven expansion of the boiler reflects the unbalanced medium temperature and medium flow velocity in all directions of the boiler. When the boiler is designed, the expansion of the symmetrically distributed pipes needs to be kept symmetrical basically, and the fluid flowing inside the symmetrically distributed pipes is kept balanced basically, so that the balance of the whole boiler is lost.
In addition, regarding the boiler expansion rate alarm, specifically, according to the above boiler expansion rate calculation method, when the expansion rate of the boiler expansion measurement point obtained by calculation reaches a preset alarm value, where the preset alarm value is a numerical value related to the boiler metal material, the boiler size, and the like, and specific calculation is required for the specific boiler, and may be set to 102% -105% of the rated expansion rate, the boiler expansion rate alarm is issued. The expansion rate is divided into two types, one is the outward expansion rate when the boiler is heated up, and the other is the contraction rate when the boiler is cooled down. The rate of boiler expansion reflects the amount of stress generated during the boiler expansion process.
In addition to the above embodiments, the present invention further includes:
counting the boiler fatigue degree, and when the boiler metal fatigue value (N +1) of a region represented by a certain expansion measuring point is greater than a preset fatigue value, maintaining the metal pipe in the region;
boiler metal fatigue score (N +1) ═ boiler metal fatigue score (N) + boiler expansion score pulse coefficient 1+ boiler expansion rate pulse coefficient 2;
wherein, the metal fatigue score (N +1) of the boiler is the latest metal fatigue score of the boiler, and the metal fatigue score (N) of the boiler is the metal fatigue score of the last boiler; the boiler expansion counting pulse is 1 or 0, when the expansion amount of the expansion measuring point is greater than the rated expansion amount or the contraction amount is less than the preset contraction amount, counting is carried out, the boiler expansion counting pulse sends a pulse, the pulse is changed from 0 to 1, and then recovery is carried out; the boiler expansion rate pulse is 1 or 0, when the expansion rate of the expansion measuring point exceeds a preset expansion rate, the boiler expansion rate pulse is changed from 0 to 1, and then the boiler expansion rate pulse is recovered; the coefficients 1 and 2 are empirical values.
Further, the coefficient 1 is an empirical value representing the amount of metal fatigue of the boiler caused by expansion changes of the boiler, and the large metal material shrinkage inevitably causes the increase of the metal fatigue. The specific score is determined according to the habits of the user, as long as in the scoring rule, all parameter scoring principles are consistent, and the metal fatigue increment represented by the same score is equivalent; the coefficient 2 is a function related to the maximum expansion rate of the boiler, the higher the maximum expansion rate of the boiler is, the larger the coefficient 2 is, the rapid metal expansion and contraction inevitably causes the increase of the fatigue degree of the metal, and the fatigue degree increases more at higher speed. The specific score is determined according to the habits of the user, and the metal fatigue increment represented by the same score is equivalent as long as the score is consistent with other parameter scoring principles in the scoring rule. The functional relationship between the coefficient 2 and the expansion rate is related to the characteristics of metal materials of the boiler, the size of the boiler and the like, and the specific boiler is determined specifically.
Specifically, in the operation of the boiler, the method counts the times of heating expansion and cooling contraction of the boiler. The statistical rule is that the temperature rise expansion is recorded once when the expansion amount reaches a preset value in the temperature rise process of the boiler, and the temperature reduction shrinkage is recorded once when the shrinkage amount reaches a preset value in the temperature reduction process of the boiler. The preset quantity value is a quantity value related to the metal material of the boiler, the size of the boiler and the operation parameters of the boiler and is specifically calculated according to the characteristics of the boiler. Can be set to 10-30% of the maximum expansion of the boiler. When the expansion and contraction times of the boiler are counted, the method counts the times that the expansion rate of the boiler exceeds the preset rate and can be set to be 102% -105% of the rated expansion rate, and simultaneously records the maximum expansion rate at this time. According to the boiler expansion times and the times that the boiler expansion rate exceeds the early warning value, the method comprehensively analyzes the metal fatigue degree of the boiler and provides the metal fatigue degree represented by the value.
Further, the metal fatigue value of the boiler is respectively calculated by the expansion amount monitored by different expansion measuring points of the boiler, and because each expansion measuring point represents the metal expansion condition of a region when the expansion measuring points of the boiler are designed, the metal fatigue condition of the region can be represented by the expansion measuring points. Of course, the local signals can be combined to analyze the condition of the whole boiler.
Besides the boiler expansion monitoring method, the invention also provides a boiler expansion monitoring system.
The boiler expansion monitoring system comprises expansion monitoring devices, a controller 500, expansion monitoring instruments used for displaying real-time expansion data of all expansion measuring points and a server 400 used for executing image display or alarm execution, wherein the number of the expansion monitoring devices is consistent with the number of the selected expansion measuring points, and the controller 500 is used for executing the boiler expansion monitoring method. The expansion monitoring instrument is positioned at the accessory of the corresponding monitoring device and can display the expansion data of the corresponding expansion measuring point in real time.
The boiler expansion monitoring system that this embodiment provided, its expansion monitoring instrument is installed near boiler expansion measuring point, and an expansion monitoring instrument is a unit with a set of expansion monitoring device, and the expansion monitoring instrument is used for gathering the expansion data of corresponding unit, when realizing showing the function on the spot, transmits the signal for expansion monitoring system's server 400 through field bus, and expansion monitoring system server 400 communicates through field bus or RS485 protocol with DCS control system or PLC control system.
Further, the boiler expansion monitoring system acquires real-time data from the outside in three aspects:
1. the expansion data of each expansion point monitored by a field expansion monitoring instrument;
2. the temperature and pressure of the main monitoring points of the boiler are collected from the DCS system or the PLC system, and comprise main and reheat steam temperature and pressure, boiler wall temperature, steam drum temperature and pressure, and header temperature and pressure, and the like, including but not limited to the expansion measuring points. The boiler expansion monitoring system can also detect the above signals by itself when conditions permit.
3. The method comprises the following steps of collecting data of boiler loads, such as main steam flow, loads of main pipelines, such as steam or water flow, unit loads and the like from a DCS (distributed control system) system or a PLC (programmable logic controller) system, and mainly using the data for carrying out comparative analysis. And comprehensively analyzing boiler expansion influence factors by simultaneously reading the data and the variation trend and combining the boiler expansion condition. The boiler expansion monitoring system can also detect the above signals by itself when conditions permit.
The data such as temperature, pressure, flow and the like collected by the monitoring, calculation and DCS system are stored in a historical database as historical data and can be retrieved together with other data. The operation temperature of each part of the boiler is collected from a boiler operation monitoring system or a DCS system, the design data of a boiler design unit is combined, and the thermal stress and the metal fatigue of each key part of the system are calculated according to the structure of the boiler system, so that the operation guidance of the boiler system and the analysis of the service life of metal materials are realized.
Further, as shown in fig. 4, the present embodiment provides an expansion monitoring device in an expansion detection system, which includes a detection component 100 and a variation component 200. The variable component 200 is mounted on the object to be detected, a plurality of expansion measurement points are arranged on the object to be detected, the variable component 200 is mounted on each expansion measurement point, when the expansion measurement points of the object to be detected expand, the position of the variable component 200 changes accordingly, and the detection component 100 acquires the expansion condition of the object to be detected by acquiring the displacement of the variable component 200.
Specifically, the detection assembly 100 includes a main body frame 101, a probe holder 102, and a displacement sensor. The main body frame 101 is used for installing the probe bracket 102, the probe bracket 102 is used for installing the displacement sensor, and the displacement of the main body frame 101 should be fixed, for example, the main body frame 101 can be directly welded on a boiler steel frame, and can also be used as an extension member of the fixed part of the existing mechanical boiler expansion monitor and connected with the boiler steel frame; the number of the displacement sensors is at least three, and displacement amounts of the varying assembly 200 in the X, Y, Z direction are respectively acquired, so that the detection assembly 100 becomes a multi-dimensional displacement detection assembly, and detection accuracy is improved. Further, the shifting assembly 200 may be directly welded to the boiler expansion member or may be an extension of the movable finger portion of the original mechanical boiler expansion monitor and connected thereto.
Specifically, the object to be detected may be a boiler, or an accessory device such as a steam pipe, a water supply pipe and a related header related to the boiler.
Further, the main frame 101 at least includes three plate bodies perpendicular to each other, each plate body is hinged with at least one probe support 102, one end of the probe support 102 is adjustably disposed on the plate body, the displacement sensor is mounted at the other end of the probe support 102, and the probe support 102 should be fixed to the main frame 101 after being adjusted to the optimal position.
On the basis of the above embodiments, an arc-shaped groove is formed on the plate body, a strip-shaped groove is formed on the probe bracket 102, and the length of the strip-shaped groove is greater than the radius of the arc-shaped groove; the probe bracket 102 can swing along the arc-shaped groove, and the intersection of the arc-shaped groove and the strip-shaped groove can move along the extending direction of the strip-shaped groove. By the arrangement, the angle adjustment of the probe bracket 102 and the adjustment of the relative displacement with the main body frame 101 can be realized, and the position adjustment of the displacement sensor is further realized, so that the displacement sensor is in the best detection position. Furthermore, a center hole is formed in the plate body and located at the center of the arc-shaped groove, and the center hole is rotatably connected with the intersection of the strip-shaped groove of the probe support 102, so that the probe support 102 can swing conveniently, and angle adjustment is achieved. Preferably, the strip-shaped groove and the central hole are fixed through a first connecting piece 104, and the intersection of the strip-shaped groove and the arc-shaped groove is fixed through a second connecting piece 105. Preferably, the first connecting member 104 and the second connecting member 105 are both screw and nut mating members.
On the basis of the above embodiments, the plate body is a right-angled triangular plate body, and the right-angled sides of the right-angled triangular plate bodies are connected in sequence; a triangular plane is arranged at the intersection of the plate bodies of the main body frame 101, and a frame fixing rod 103 is arranged on the triangular plane. Alternatively, the frame fixing rod 103 is installed at the joint of two right-angled triangular plates, and the extending direction of the frame fixing rod 103 is parallel to the connecting edge. Of course, the frame fixing rod 103 may be installed at other positions, and in this embodiment, a triangular plane does not need to be provided at the plate body intersection of the main body frame 101.
Specifically, the main frame 101 is used as a fixing support of the multi-dimensional displacement sensor, and comprises three orthogonal metal plates which form the main frame 101, and the three metal plates are rigidly welded, namely three right-angled triangles are welded together. An arc-shaped groove is designed on each metal plate, a center hole is formed in the center of the arc-shaped groove, and a probe support 102 is respectively installed on the center hole. The probe holder 102 is used to mount a displacement sensor thereon, and specifically, the displacement sensor may be fixed thereto by screws, or may be fixed thereto in other manners, which is determined according to the structure of the displacement sensor, but the displacement sensor should be perpendicular to the corresponding surface of the displacement changing block 201. A rectangular groove is formed at the fixed end of the probe holder 102, the junction of the three metal plates of the main body frame 101 is formed as a triangular plane as shown in fig. 2 to 3, and a metal bar, i.e., a frame fixing bar 103, is welded thereto for fixing the main body frame 101 to a target member. The probe holder 102 can be rotated about the center hole, and can be adjusted in the front-rear direction. When the position of the probe holder 102 is determined, the probe holder 102 can be fixed to the main body frame 101 by the first connector 104 and the first connector 104; the specific method comprises the following steps: one screw penetrates through the intersection of the central hole of the main body frame 101 and the rectangular groove of the probe bracket 102, the other screw penetrates through the intersection of the rectangular groove of the probe bracket 102 and the arc-shaped groove of the main body frame 101, and the two screws are tightened by using connecting nuts respectively. When the position of the probe bracket 102 needs to be adjusted, the two nuts are loosened.
In addition to the above embodiments, the variable unit 200 includes a displacement variable block 201 and a variable block fixing rod 202, and the variable block fixing rod 202 is attached to the object to be detected; the displacement change block 201 is in a cuboid shape, or is formed by vertically welding three rectangular plates in pairs, the detection component 100 is located at the corner of the displacement change block 201, and three surfaces at the corner of the displacement change block 201 correspond to at least one displacement sensor. Preferably, the multidimensional displacement variation block 201 is a rectangular or cubic hollow metal block, and of course, other structures can be formed with three surfaces perpendicular to each other; a metal rod is welded at the center of one plane of the displacement varying block 201 for fixing the displacement varying block 201 on a target member, and when the displacement varying block 201 is formed by vertically welding three rectangular plates two by two, the metal rod may be welded at one of the joints. Above-mentioned setting, through the setting of displacement change piece 201 of cuboid type, only need set up detecting element 100 in the corner of displacement change piece 201, alright obtain displacement volume of displacement change piece 201 in X, Y, Z orientation with accurate efficient, be convenient for install detecting element 100.
In addition to the above embodiments, the displacement sensor is a non-contact sensor such as a laser displacement sensor or an ultrasonic displacement sensor, but of course, the displacement sensor may be a rebound linear displacement sensor, and a roller ball is provided at an end of the rebound linear displacement sensor and abuts against the variable assembly 200.
Specifically, the displacement sensor is mounted on the probe holder 102 of the main body frame 101, and the displacement sensor may be a resilient LVDT. The fixed end of the rebound type LVDT provided by the embodiment is fixed on the probe support 102, the position of the rebound type LVDT is fixed, the rebound type pull rod abuts against one surface of the displacement variable block 201 and keeps vertical, and the expansion variable block is generally arranged at four corners of the boiler in the expansion process of the boiler, and the expansion of the expansion variable block does not have rotary displacement, so that the rebound type LVDT is always vertical to the probe support 102 of the displacement measuring device. When the boiler expands unevenly, the expansion block rotates by a small displacement, and the probe holder 102 is expected to be still approximately vertical, so the influence on the measurement result is negligible. In order to ensure that the contact surface between the pull rod and the displacement change block 201 does not generate hard destructive friction, a ball is added at the head of the pull rod to meet the requirement of the displacement change block 201 on transverse movement, and the head of the probe rod is designed into a ball form to avoid the deformation of the pull rod caused by strong transverse friction. At this time, although the displacement change block 201 generates transverse displacement, the pull rod is always vertical to the plane of the displacement change block, so that equipment abrasion and pull rod deformation caused by hard friction when the horizontal position changes are eliminated; the arrangement is simple and convenient to install and simple in structure, the LVDT can be always kept perpendicular to the surface of the displacement variable block 201, and the measurement precision is ensured.
The multidimensional expansion monitoring device provided by the embodiment is simple and convenient to install, can be used for simply and conveniently debugging signals, realizes diversity of signal transmission, and is convenient for integration of monitoring signals of a large number of expansion measuring points; in addition, the in-situ multidimensional expansion monitoring instrument and the field bus technology are utilized, the number of cables is greatly reduced, and meanwhile, the construction cost is reduced, so that the construction cost of the boiler expansion monitoring system is greatly reduced, and conditions are created for the practical application of the technology.
The boiler expansion monitoring method and system provided by the invention are described in detail above. The principles and embodiments of the present invention are explained herein using specific examples, which are presented only to assist in understanding the method and its core concepts. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.
Claims (10)
1. A boiler expansion monitoring method, comprising the steps of:
selecting an expansion dead point and a plurality of expansion measuring points on the boiler, and establishing a three-dimensional coordinate system by taking the expansion dead point as an origin;
acquiring real-time expansion data of each expansion measuring point;
calculating real-time expansion data of each target expansion point on the boiler according to the corresponding real-time expansion data of the expansion measurement points;
acquiring pressure, temperature and variation thereof at each expansion measuring point, and determining theoretical expansion amount of the expansion measuring points;
calculating the theoretical expansion amount of each target expansion point on the boiler according to the corresponding theoretical expansion amount of the expansion measurement point;
and judging whether the running state of each target expansion point on the boiler is normal or not according to the real-time expansion data of each target expansion point and the calculated theoretical expansion amount.
2. The boiler expansion monitoring method according to claim 1, wherein the calculating real-time expansion data for each target expansion point on the boiler based on the real-time expansion data for each expansion measurement point comprises:
determining the coordinate of a target expansion point to be calculated before expansion;
selecting coordinates of a corresponding reference expansion measuring point before expansion and real-time expansion data of the reference expansion measuring point;
performing equal proportion calculation according to the position relationship between the target expansion point and the expansion dead point before expansion, the position relationship between the reference expansion measurement point and the expansion dead point before expansion and the position relationship between the reference expansion measurement point and the expansion dead point after expansion to obtain real-time expansion data of the target expansion point;
the calculating the theoretical expansion amount of each target expansion point on the boiler according to the corresponding theoretical expansion amount of the expansion measurement point comprises the following steps:
determining the coordinate of a target expansion point to be calculated before expansion;
selecting coordinates of a corresponding reference expansion measuring point before expansion and theoretical expansion data of the reference expansion measuring point;
performing equal proportion calculation according to the position relation between the target expansion point and the expansion dead point before expansion, the position relation between the reference expansion measurement point and the expansion dead point before expansion and the position relation between the reference expansion measurement point and the expansion dead point after expansion to obtain theoretical expansion data of the target expansion point;
the reference expansion measurement point is the closest expansion measurement point ahead of the target expansion point with respect to the expansion direction of the expansion dead point;
the reference expansion measurement point is a closest expansion measurement point ahead of the target expansion point with respect to an expansion direction of the expansion dead point.
3. The boiler expansion monitoring method according to claim 2, wherein the coordinate of the reference expansion measurement point before expansion is set as x0，y0，z0(ii) a Coordinate x of the target expansion point before expansion01，y01，z01(ii) a When the real-time expansion amount monitored by the expansion measuring point is delta x0、Δy0、Δz0Then x01，y01，z01The expansion values of (a) are:
Δx01＝(x01/x0)*Δx0；
Δy01＝(y01/y0)*Δy0；
Δz01＝(z01/z0)*Δz0。
4. the boiler expansion monitoring method according to claim 1, further comprising:
setting a measurement period, and acquiring real-time expansion data of each expansion measurement point in each measurement period;
and acquiring a dynamic three-dimensional image when the boiler expands according to the original shape and the original size of the boiler and the real-time expansion data of each expansion point.
5. The boiler expansion monitoring method according to any one of claims 1 to 4, further comprising:
and when the real-time expansion data of each target expansion point on the boiler is smaller than the preset allowable range of the theoretical expansion amount, sending an expansion blocking alarm signal.
6. The boiler expansion monitoring method according to any one of claims 1 to 4, further comprising:
selecting a plurality of target expansion points as the same group of target expansion points according to the shape of the boiler;
and when the difference between the real-time expansion data of one target expansion point in the same group of target expansion points and the real-time expansion data of any other target expansion points in the same group is 5% -10%, sending out an uneven expansion alarm signal.
7. The boiler expansion monitoring method according to any one of claims 1 to 4, further comprising:
determining a nominal expansion rate from the temperature and pressure at the expansion measurement point;
and when the expansion rate of each target expansion point on the boiler is greater than the rated expansion rate, sending an expansion rate alarm signal.
8. The boiler expansion monitoring method according to claim 7, wherein the expansion rate of each target expansion point on the boiler comprises:
the rate of outward expansion of each target expansion point when the boiler is heated and/or the rate of contraction of each target expansion point when the boiler is cooled.
9. The boiler expansion monitoring method according to any one of claims 1 to 4, further comprising:
counting the boiler fatigue degree, and when the boiler metal fatigue value (N +1) of a region represented by a certain expansion measuring point is greater than a preset fatigue value, maintaining the metal pipe in the region;
boiler metal fatigue score (N +1) ═ boiler metal fatigue score (N) + boiler expansion score pulse coefficient 1+ boiler expansion rate pulse coefficient 2;
wherein, the metal fatigue score (N +1) of the boiler is the latest metal fatigue score of the boiler, and the metal fatigue score (N) of the boiler is the metal fatigue score of the last boiler; the boiler expansion counting pulse is 1 or 0, when the expansion amount of the expansion measuring point is greater than the rated expansion amount or the contraction amount is less than the preset contraction amount, counting is carried out, the boiler expansion counting pulse sends a pulse, the pulse is changed from 0 to 1, and then recovery is carried out; the boiler expansion rate pulse is 1 or 0, when the expansion rate of the expansion measuring point exceeds a preset expansion rate, the boiler expansion rate pulse is changed from 0 to 1, and then the boiler expansion rate pulse is recovered; the coefficients 1 and 2 are empirical values.
10. A boiler expansion monitoring system, comprising an expansion monitoring device, a controller, an expansion monitoring instrument for displaying real-time expansion data of each expansion measuring point, and a server for executing image display or executing alarm, wherein the controller is used for executing the boiler expansion monitoring method according to any one of claims 1 to 9.
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