US3831561A - Device for early detection of rupture of the pressure part of a boiler - Google Patents

Device for early detection of rupture of the pressure part of a boiler Download PDF

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Publication number
US3831561A
US3831561A US00397355A US39735573A US3831561A US 3831561 A US3831561 A US 3831561A US 00397355 A US00397355 A US 00397355A US 39735573 A US39735573 A US 39735573A US 3831561 A US3831561 A US 3831561A
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Prior art keywords
boiler
sound wave
wave transmission
tube
soot
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Expired - Lifetime
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US00397355A
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English (en)
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T Yamamoto
K Yasukouchi
R Sato
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Mitsubishi Heavy Industries Ltd
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Mitsubishi Heavy Industries Ltd
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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

Definitions

  • the device is adapted for use in an atmosphere, such as a recovery boiler, which is liable to contamination, and comprises a gate circuit for shutting a sound wave transmission tube and shutting an output of a microphone upon actuation of soot blowers of the boiler so as to protect the device against detrimental effects imposed thereon by the operation of the soot blowers, means for cleaning the transmis sion tube by passing pressurized air therein while the output of the microphone is being shut down, means for cooling the sound wave transmission tube, means for detecting an abnormal condition of the microphone by passing pressurized air in the vicinity of said microphone and means for detecting clogging of the sound wave transmission tube by pressure.
  • a gate circuit for shutting a sound wave transmission tube and shutting an output of a microphone upon actuation of soot blowers of the boiler so as to protect the device against detrimental effects imposed thereon by the operation of the soot blowers, means for cleaning the transmis sion tube by passing pressurized air therein while the output of the microphone is being shut down, means for cooling the sound
  • Abnormal conditions of the boiler caused by water or steam intruding into the boiler furnace from the pressure part of the boiler include abnormal sound waves andvibrations occurring incident to the intrusion of the water or steam, and, when the boiler is a soda recovery boiler, an increase of the steam partial pressure in the furnace gases and the generation of hydrogen due to the reaction between the smelt deposited on the furnace wall and the spouting water or steam.
  • a rupture of the boiler pressure part can be detected early by sensing the abnormal vibrations occurring incident to the spouting of water or steam from the boiler pressure part. Namely, when a rupture has occurred at the pressure part of the boiler for any reason and the water or steam spouts from the opening of said rupture at sonic or supersonic speed, abnormal sound waves and vibrations are generated at or in the vicinity of the rupture opening.
  • the frequencies of the abnormal sound waves and vibrations are as high as 20 KH and the vibrations in such a high frequency range are propagated in steel member connected to the pressure part of the boiler and reach a detection end provided at a suitable position of the boiler structure. The detection end detects the abnormal vibrations transmitted directly in the steel member.
  • soot-blow i.e., blowing the boiler with pressurized steam
  • the amount of pressurized steam used for soot-blow is so large as compared with the mount of steam to be detected spouting from the rupture at the pressure part that the detection of the abnormal vibrations is extremely difficult while being interfered by soot-blow.
  • One boiler is usually provided with 10 to 20 soot blowers which are operated sequentially (the operating time of each soot blower being 2 to 10 minutes) to complete one cycle of sootblow in a period of l to 2 hours.
  • soot-blow In an ordinary utility boiler, two to three cyclic operations of the soot blowers once every day are sufficient for soot-blow and a detecting device for detecting the vibrations or sound wave generating incident to the spouting of water or steam can operate normally during the rest of the time.
  • a detecting device for detecting the vibrations or sound wave generating incident to the spouting of water or steam can operate normally during the rest of the time.
  • soot-blow in case of boilers, such as a soda recovery boiler, in which the amount of depositing soot is large, soot-blow must be carried out continuously almost all day long, and in case of the soda recovery boiler in particular, the correct detection of water or steam leakage is quite difiicult, despite the fact that water or steam leakage ,will possibly result in a serious accident.
  • Part of the sound wave is absorbed by the watercooled pipe and other members connected to the furnace, but the other part propagates in air and reaches a sound wave detector or the like provided at a suitable location of the furnace wall.
  • This sound wave is at a level equal to or several times that of the dark ground noise of the boiler in the frequency range from a low frequency of about 3 KH to a supersonic frequency of 20 KH Therefore, the spouting sound can be detected relatively simply from the dark ground noise of the boiler by detecting the sound wave and passing it through a sound filter of a suitable frequency range. In this way, it becomes possible to detect a slight water or steam leakage which cannot be detected from the vibration transmitted in the boiler structure. To prove this, the present inventor conducted an experiment in which a pressure pipe (indicated at numeral 01 in FIG.
  • the present inventor at first made an attempt to confirm through experiment that air can be used in lieu of water and steam, and found that the frequency spectrum of the sound wave generated by pressurized air of 5 kg/cm spouting from a 5 mm diameter opening is very close to the frequency spectra of the sound waves generated by saturated water and saturated steam of a pressure of kg/cm spouting from an 0.5 mm diameter opening, and that air is well usable as a substitute for water and steam.
  • the present inventor conducted an experiment using air over the entire region of the boiler, and confirmed that air can be sufficiently usable even in the actual boiler. Namely, compressed air of a pressure of 5 kg/cm wasdischarged from a 5 mm diameter opening at the position of each of a starting burner nozzle (indicated by numeral 04 in FIG. 1) and a black liquid spray nozzle (indicated by numeral 05 in FIG. 1) and the pressure levels of the generated sounds in the frequency range from 3 to 20 KH were sensed by a sound detection end 07 provided at the outlet of the furnace and recorded on linear coordinates, with the result shown in FIG. 5. The sounds had sufficient sound pressure levels as indicated at a and b in FIG. 5. This also means that spouting of water or steam from an 0.5 mm diameter opening can be well detected.
  • the present invention has for its object the provision of a device adapted for use with a general boiler for detecting promptly a spouting of water into the boiler furnace due to rupture of the pressure part of the boiler and thereby for minimizing the chance of accident, the device when used with a soda recovery boiler enabling the operator to detect the intrusion of water or steam into the boiler furnace early and positively, to stop the boiler upon occurrence of such condition and thereby to preclude a dangerous accident of the boiler.
  • Another object of the invention is to provide a device of the character described above, which is provided with means for enabling the device to maintain its normal detecting function without being affected by the operation of soot blowers.
  • Still another object of the invention is to provide a device of the character described above, which is provided with means for cleaning the device with pressurized air so as to enable the device to maintain its normal detecting function even when used in an atmosphere liable to contamination, such as a soda recovery boiler.
  • Still another object of the invention is to provide a device of the character described above, which is provided with means for determining whether a microphone to detect a sound wave generating as a result of rupture of the pressure part is in the normal operative state or not.
  • a further object of the invention is to provide a device of the character described above, which is provided with means for detecting a clogging of the device due to contamination soda to ensure the satisfactory function of the device even when the device is used in an atmosphere liable to contamination.
  • An additional object of the invention is to provide a device of the character described above, which is thermally protected and has a high detection sensitivity.
  • FIGS. 1 5 are diagrams for explaining the background of the present invention, of which:
  • FIG. I is a diagram for explaining a setup which was used for examining the boiler pressure part rupture detecting effect of the subject device in a conventional soda recovery boiler;
  • FIG. 2 is a diagram exemplifying a comparison between the frequency spectra of the normal vibration of the boiler and an abnormal vibration of the same due to rupture;
  • FIG. 3 is a diagram exemplifying a comparison between the frequency spectra of the dark ground noise of the boiler and an abnormal noise of the same due to rupture;
  • FIG. 4 is a diagram exemplifying a comparison between the frequency spectra of the water, steam and air gushing sounds
  • FIG. 5 is a diagram exemplifying a recorded air gushing sound at the boiler furnace part
  • FIG. 6 is a view exemplifying the position of the device according to the present invention as applied to a soda recovery boiler;
  • FIG. 7 is a block diagram illustrating briefly the construction of the device according to the invention.
  • FIGS. 8 and 9 are views exemplifying a preferred embodiment of the device of the invention.
  • FIG. 10 is a flow sheet for explaining the operation of the device of this invention.
  • FIG. 6 shows a portion of the soda recovery boiler, in which reference numeral 1 designates a boiler furnace tube, 2 a superheater, 3 a boiler tube, 4 an economizer, 5 manholes, 6 a peep hole and 7 the location of a sound wave detection head.
  • FIGS. 8 and 9 exemplify the practical construction of a fixed type sound wave detection head which is to be disposed, for example, at the position 7 in FIG. 6.
  • the detection head generally indicated by numeral 11 comprises an air-cooled sound wave transmission tube 12, an electric three-way valve 13, a sound wave transmission tube 14 and a microphone 15. Since this detection head 11 is left mounted on the furnace wall, particular consideration is given thereto to render it resistive to heat and dust proof.
  • a cooling chamber 16 is provided around the sound wave transmission tube 12 for cooling tube 12 with air.
  • the provision of the cooling chamber 16 is advantageous in reducing the length of the transmission tube 12 and achieving detection with high sensitivity, without attenuating a high frequency sound wave to be detected.
  • Reference numeral 17 designates a cooling air inlet tube; 18 a pressure regulator for the flow rate of the cooling air so as to eliminate detrimental effect on the detecting device of the noise which would be generated by the flow of cooling air when the: flow rate of cooling air is excessively high; 19 a reference leakage sound generating hole for generating a reference leakage sound which is used for checking a performance degradation of the microphone or an abnormal operation of the detecting device; 20 an inlet tube for leakage sound generating air; 21 an electric air valve for opening and closing the leakage sound generating air passage; and 22 a branch tube diverging from the cooling air inlet tubel7.
  • a flashing air inlet chamber 23 is provided for injecting flashing air into the sound wave transmission tube 12 in four directions.
  • Reference numerals 24 and 25 designate a flashing air inlet tubes.
  • the electric three-way valve 13 is provided between the sound wave transmission tubes 12 and 14, which severs communication between the sound wave transmission tubes 12 and 14 to shut down the transmission of sound wave to the microphone 15 and establishes communication between said sound wave transmission tube 12 and the flashing air inlet tube 25, at the time of soot blow, providing for passage of flashing air in said flashing air inlet tube 25 and sound wave transmission tube 12 through an electric air valve 26 which is then open.
  • a pressure sensor 28 is provided for issuing an alarm in the event when the sound wave transmission passage has clogged with soot attaching to the inlet portion of the sound wave transmission tube 12.
  • This pressure sensor 28 is designed such that it will issue an alarm when the pressure difference between the internal pressures of the sound wave transmission tubes 12 and the furnace, or the internal pressure of the sound wavetransmission tube 12 reaches a certain level.
  • Reference numerals 27 and 29 designate tubes for supplying the internal pressures of the furnace and sound wave transmission tube to pressure sensor 28..
  • Reference numeral 30 designates a bracket for mounting the microphone on the sound wave transmission tube 14, which is made of a heat insulating material; 31 an Oring; 32 a cooling air outlet tube; 1 a furnace cooling water tube; 34 a heat insulating material and 35 a housing.
  • FIG. 10 shows a block diagram of an example of the detecting device of the invention for explaining the operation principle of the device.
  • the detecting device shown comprises a band-pass filter 36, a gate 37 opened and closed in response to signals from control means 38, a monitor and a soot blower controller which generates signals for actuating and stopping soot blowers.
  • the operation of the soda recovery boiler is accompanied by heavy attachment of soot and calls for repetitive soot-blow operations. Therefore, the detection of the leakage sound has to be made in the interval between the soot-blow operations.
  • the electric three-way valve 13 is actuated by the signal from the controller 38 and the sound wave transmission passage leading to the microphone is shut down by said valve, to prevent overloading of the microphone. Then, the electric valve 26 is opened to flash the sound wave transmission passage.
  • the gate 37 is held closed to shut down the transmission of a signal from the band-pass filter 36 to the monitor 39 and thereby to prevent erroneous operation of the detecting device otherwise caused by the noises from the soot blower and flashing air flow.
  • the electric valve 26 is closed concurrently with the termination of the operation of the first soot blower and, therefore, flashing of the sound wave transmission passage ends. Then, the electric three-way valve 13 is actuated to open the sound wave transmission passage leading to the microphone l5 and the gate 37 is also opened. If water or steam is spouting through a rupture formed in the boiler pressure tube'in this case, such condition is detected by the sound wave detection head 11 and transmitted to the monitor 39 through the bandpass filter 36 in the form of a high frequency signal.
  • the second soot blower is set in operation, whereupon the electric three-way valve 13 is actuated to shut down the sound wave transmission passage leading to the microphone and concurrently the gate 37 is closed and the electric valve 26 is opened, so that the sound wave transmission passage is flashed again.
  • the interval between the termination of operation of the first soot blower and the start of the second soot blower is only about 30 to 100 seconds. With the detecting device of the invention, however, it is possible to monitor the boiler periodically all day long by making use ofsuch a short period of time.
  • the detecting device of the invention is provided with pressure sensor 28 for detecting clogging of the inlet portion of the sound wave transmission passage l2 by soot.
  • This pressure sensor 28 transmits a signal to the controller informing it of heavy deposition of soot, when the internal pressure of the sound wave transmission tube 12 or the pressure difference between the internal pressures of said sound ave transmission tube and the furnace, at the time of sootblow, has reached a preset value;
  • the electric three-way valve 13 is actuated to close the sound wave transmission passage leading to the microphone and the electric valve 21 is opened, either automatically from the controller 38 or manually, at a suitable time when the soot blowers are not in operation, and thereby air is caused to discharge from the reference leakage sound generating hole shown in FIG. 8 to generate the reference leakage sound, and concurrently the gate 37 is opened.
  • An alarm is issued indicating the performance of the microphone being degraded or the operation of the detecting device being abnormal, when the leakage sound is below a preset level.
  • the overheater or the economizer of the soda recovery boiler upon occurrence of a rupture in the pressure tube and an abnormal sound wave has been generated, the abnormal sound wave spreading in air, upon reaching the microphone 15, is immediately converted into an electric signal which is discriminated from the electric signal, created from the dark noise of the boiler, by the band-pass filter 36 and transmitted to the monitor 39 through the gate 37 which is then open.
  • the monitor 39 upon receiving such electric signal, transmits a signal to alarm means, such as a buzzer or a lamp, to actuate the same, to means for automatically stopping the boiler, or to the soot blower controller 40 for stopping the soot blowers only.
  • alarm means such as a buzzer or a lamp
  • soot blower controller 40 for stopping the soot blowers only.
  • an arrangement may be made such that the monitor, upon receiving the electric signal, will continue its monitoring operation for a while and transmit the alarm actuating signal or boiler stopping signal after confirming that the boiler is in a dangerous condition.
  • the detecting device of the invention monitors constantly an abnormal condition of the boiler by detecting the sound wave, generating from water or steam leaking from the boiler pressure tube and spreading in air or trapped in the furnace, by the detection head attached to the furnace wall, converting the sound wave into electric signals and discriminating the electric signal from the signals originating from the dark ground noises of the boiler by the band-pass filter.
  • the device of the invention it is possible to detect the occurrence of a rupture of the pressure part, such as the water tube, of the boiler early and positively, and upon detecting the abnormal sound wave, the device converts it into an electric signal, or pneumatic or hydraulic signal which is transmitted to the alarm means or explosion preventing means to actuate the same automatically, whereby the occurrence of explosion in the boiler furnace can be avoided and thereby heavy damages to the facility as well as persons can be avoided which would otherwise be caused by the explosion.
  • a device for early detecting a rupture of the pressure part of a recovery boiler having soot blowers comprising:
  • a sound wave transmission tube open at its forward end in the furnace of the recovery boiler and connected at its rear end through a three-way valve to a conduit having a microphone disposed therein,
  • control means for closing said gate circuit, opening said further valve and operating said three-way valve to communicate said sound wave transmission tube with said further valve before the start of soot-blow of said recovery boiler, and for opening said gate circuit, closing said further valve and operating said three-way valve to communicate said sound wave transmission tube with said conduit after the termination of soot-blow.
  • a device in which means is additionally provided for injecting pressurized air into said conduit from a nozzle through another valve.
  • a device in which means is provided for detecting a pressure difference between the pressure in the rear end portion of said sound wave transmission tube and the pressure in the other end portion of said sound wave transmission tube open in said furnace.
  • a device in which means is provided for cooling said sound wave transmission 10' tube.
  • microphone means for detecting an acoustical wave in said tube and producing an electrical signal
  • a band-pass filter connected to said microphone means and receiving said electrical signal
  • Apparatus as in claim 5 including means for detecting a pressure differential between the pressure in the rear portion of said tube and the portion of said tube open in said boiler.
  • Apparatus as in claim 5 further including means for supplying a stream of air into said open end of said tube when said soot blowers are operating to prevent clogging.
  • Apparatus as in claim 5 further including means for providing a flow of air into said tube adjacent said microphone means to simulate rupture and check said
US00397355A 1972-09-25 1973-09-14 Device for early detection of rupture of the pressure part of a boiler Expired - Lifetime US3831561A (en)

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JP9590772A JPS5344601B2 (ja) 1972-09-25 1972-09-25

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US (1) US3831561A (ja)
JP (1) JPS5344601B2 (ja)
CA (1) CA979112A (ja)
FI (1) FI58970C (ja)
SE (1) SE389724B (ja)

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4466383A (en) * 1983-10-12 1984-08-21 The Babcock & Wilcox Company Boiler cleaning optimization with fouling rate identification
US4475482A (en) * 1982-08-06 1984-10-09 The Babcock & Wilcox Company Sootblowing optimization
US4498333A (en) * 1983-06-01 1985-02-12 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Carbon granule probe microphone for leak detection
US4526135A (en) * 1984-02-03 1985-07-02 Westinghouse Electric Corp. Eddy current workpiece positioning apparatus
US4624220A (en) * 1981-04-30 1986-11-25 Olsson Mats A Infrasound generator
US4901678A (en) * 1987-11-04 1990-02-20 Econosto N.V. Heating boiler and method for operating same
US4960079A (en) * 1989-08-03 1990-10-02 Marziale Michael L Acoustic leak detection system
US4979820A (en) * 1989-04-24 1990-12-25 Parthasarathy Shakkottai Apparatus for the remote detection of sounds caused by leaks
US4998439A (en) * 1990-01-08 1991-03-12 Westvaco Corporation Acoustic wave guide
US5101774A (en) * 1989-08-03 1992-04-07 Westvaco Corporation Acoustic leak detection system
US5351655A (en) * 1994-01-18 1994-10-04 The Babcock & Wilcox Company Acoustic emission signal collector manifold
US20040075561A1 (en) * 1999-06-07 2004-04-22 Traptec Corporation Graffiti detection system and method of using the same
US20070272130A1 (en) * 2006-05-24 2007-11-29 Lars Eriksson Apparatus for cleaning a smelt spout of a combustion device
US20120186745A1 (en) * 2011-01-26 2012-07-26 Hitachi High-Technologies Corporation Plasma processing apparatus
US20160025600A1 (en) * 2014-07-25 2016-01-28 Integrated Test & Measurement System and method for determining a location of fouling on boiler heat transfer surface
US20180187886A1 (en) * 2015-07-08 2018-07-05 Nanjing Changrong Acoustic Inc. Boiler ash remover based on combined flow
US20190041091A1 (en) * 2017-01-13 2019-02-07 Mehrzad Movassaghi Scalable pulse combustor
US10976074B2 (en) * 2019-06-27 2021-04-13 Xiamen Cheari Eco Technology Co., Ltd Safe water heater

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3376876D1 (en) * 1982-11-05 1988-07-07 Lintvalve Electronic Syst Ltd Apparatus for detecting leaks in steam raising boilers

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US2198446A (en) * 1936-08-22 1940-04-23 Babcock & Wilcox Co Waste liquor recovery apparatus
US2531159A (en) * 1948-04-15 1950-11-21 William G Rowell System for burner cutoff and signaling means upon tank leakage
US3016525A (en) * 1958-10-07 1962-01-09 Allis Chalmers Mfg Co Leak annunciator unit
US3192516A (en) * 1961-11-14 1965-06-29 Hewlett Packard Co Vibration detector
US3222635A (en) * 1962-11-13 1965-12-07 Hewlett Packard Co Ultrasonic vibration detector

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2198446A (en) * 1936-08-22 1940-04-23 Babcock & Wilcox Co Waste liquor recovery apparatus
US2531159A (en) * 1948-04-15 1950-11-21 William G Rowell System for burner cutoff and signaling means upon tank leakage
US3016525A (en) * 1958-10-07 1962-01-09 Allis Chalmers Mfg Co Leak annunciator unit
US3192516A (en) * 1961-11-14 1965-06-29 Hewlett Packard Co Vibration detector
US3222635A (en) * 1962-11-13 1965-12-07 Hewlett Packard Co Ultrasonic vibration detector

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4624220A (en) * 1981-04-30 1986-11-25 Olsson Mats A Infrasound generator
US4475482A (en) * 1982-08-06 1984-10-09 The Babcock & Wilcox Company Sootblowing optimization
US4498333A (en) * 1983-06-01 1985-02-12 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Carbon granule probe microphone for leak detection
US4466383A (en) * 1983-10-12 1984-08-21 The Babcock & Wilcox Company Boiler cleaning optimization with fouling rate identification
US4526135A (en) * 1984-02-03 1985-07-02 Westinghouse Electric Corp. Eddy current workpiece positioning apparatus
US4901678A (en) * 1987-11-04 1990-02-20 Econosto N.V. Heating boiler and method for operating same
US4979820A (en) * 1989-04-24 1990-12-25 Parthasarathy Shakkottai Apparatus for the remote detection of sounds caused by leaks
US4960079A (en) * 1989-08-03 1990-10-02 Marziale Michael L Acoustic leak detection system
US5101774A (en) * 1989-08-03 1992-04-07 Westvaco Corporation Acoustic leak detection system
US4998439A (en) * 1990-01-08 1991-03-12 Westvaco Corporation Acoustic wave guide
US5351655A (en) * 1994-01-18 1994-10-04 The Babcock & Wilcox Company Acoustic emission signal collector manifold
US20040075561A1 (en) * 1999-06-07 2004-04-22 Traptec Corporation Graffiti detection system and method of using the same
US7064664B2 (en) * 1999-06-07 2006-06-20 Traptec Corporation Graffiti detection system and method of using the same
US20070272130A1 (en) * 2006-05-24 2007-11-29 Lars Eriksson Apparatus for cleaning a smelt spout of a combustion device
US7735435B2 (en) 2006-05-24 2010-06-15 Diamond Power International, Inc. Apparatus for cleaning a smelt spout of a combustion device
US20120186745A1 (en) * 2011-01-26 2012-07-26 Hitachi High-Technologies Corporation Plasma processing apparatus
US20160025600A1 (en) * 2014-07-25 2016-01-28 Integrated Test & Measurement System and method for determining a location of fouling on boiler heat transfer surface
US9915589B2 (en) * 2014-07-25 2018-03-13 International Paper Company System and method for determining a location of fouling on boiler heat transfer surface
US20180187886A1 (en) * 2015-07-08 2018-07-05 Nanjing Changrong Acoustic Inc. Boiler ash remover based on combined flow
US10551063B2 (en) * 2015-07-08 2020-02-04 Nanjing Changrong Acoustic Inc. Boiler ash remover based on combined flow
US20190041091A1 (en) * 2017-01-13 2019-02-07 Mehrzad Movassaghi Scalable pulse combustor
US10976074B2 (en) * 2019-06-27 2021-04-13 Xiamen Cheari Eco Technology Co., Ltd Safe water heater

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JPS5344601B2 (ja) 1978-11-30
FI58970B (fi) 1981-01-30
CA979112A (en) 1975-12-02
SE389724B (sv) 1976-11-15
JPS4951401A (ja) 1974-05-18
FI58970C (fi) 1981-05-11

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