KR20160059039A - Apparatus for monitoring boiler status through sound quality assessment - Google Patents

Abstract

The present invention discloses a boiler state monitoring apparatus for monitoring a boiler state through sound quality analysis. The boiler state monitoring apparatus according to the present invention is a system for monitoring a boiler state by performing sound quality evaluation from a noise inside a boiler, An apparatus for monitoring a boiler state, comprising: an acoustic sensor unit installed in a hole from an outer wall of a boiler to collect noise inside the boiler; A signal converter for converting the sound signal collected by the sound sensor unit into a digital signal suitable for sound quality evaluation; A data processor for evaluating the sound quality of the noise from the noise converted into the digital signal by the signal converter; And a display unit for displaying an evaluation result of the data processing unit so as to confirm whether or not the boiler tube is damaged.

Description

[0001] APPARATUS FOR MONITORING BOILER STATUS THROUGH SOUND QUALITY ASSESSMENT [0002]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a boiler state monitoring apparatus, and more particularly, to a boiler state monitoring apparatus for monitoring a boiler state through evaluation of sound quality generated in a boiler.

BACKGROUND ART A boiler is a device for generating steam by heating water through combustion of petroleum or heavy oil, and is used in various forms in various industries. For example, cylindrical boilers or water tube boilers are widely used in various industries.

Here, though not shown, the cylindrical boiler is in the form of a cylinder in which a passage of a combustion furnace or a combustion gas is large, water is put around the cylinder, and the cylinder is heated, and the pressure is relatively low.

A water tube boiler is a system in which water flowing in many thin tubes is heated from the outside to flow into a tube and is converted into steam, and a high pressure medium stage can be mass-produced.

On the other hand, in the case of a water tube boiler, a high pressure is applied to the tubes installed in the boiler during the generation of the steam, and not only the high-pressure liquid or steam continues to flow inside the tube but also the high- As the tube is thinned, tube leakage occurs due to the impact. Such a tube leak initially starts with a small hole, but not only the leakage area increases with time, but also leakage of the high-pressure steam generated due to leak causes damage to the tube located next to the tube, Which causes a sudden stoppage.

Therefore, if the inside of the boiler is detected in advance and it can be planned, it can reduce many damages caused by abrupt stoppage of the boiler. For those operating boilers, it is very important to know in advance whether boiler conditions are abnormal or not.

Since it is not possible to install sensors that can detect leaks inside a high-temperature boiler, it has been used up to now to monitor the leakage of boiler tubes by installing a vibration sensor on the outside of the inner wall of the boiler. BTLD (Boiler Tube Leakage Detect) is known as a method.

However, such a conventional boiler state monitoring method is difficult to diagnose before a considerably large pressure is transmitted to the inner wall of the boiler, so there is a limit to early detection in case of leakage due to tube damage. Therefore, Sometimes, an abnormal symptom can be detected or not detected.

In a conventional boiler, a blowing operation is performed to remove the tannin attached to the inner wall of the tube. The contents of the pressure change caused by the blowing operation and the pressure change caused by the tube breakage It is difficult to accurately determine the presence or absence of a boiler tube abnormality. This is because the abnormality of the boiler tube is judged only by the pressure transmitted to the inner wall of the boiler.

In addition, if an abnormality occurs in the boiler tube, people in the field can infer that the tube breakage has occurred with an abnormal sound, but it is only to recognize that it is different from normal sound, It is impossible to grasp at all what extent the breakage is proceeding if the abnormal sound caused by the tube breakage.

SUMMARY OF THE INVENTION The present invention has been proposed in order to solve the above-described problems of the prior art, and provides a boiler state monitoring apparatus for continuously monitoring the occurrence of tube breakage by progressing sound quality evaluation for noise inside a boiler inputted through a microphone .

In order to accomplish the above object, the present invention provides a boiler state monitoring apparatus for monitoring the state of a boiler by performing sound quality evaluation from a noise inside a boiler, the apparatus comprising: An acoustic sensor unit for collecting noise; A signal converter for converting the sound signal collected by the sound sensor unit into a digital signal suitable for sound quality evaluation; A data processor for evaluating the sound quality of the noise from the noise converted into the digital signal by the signal converter; And a display unit for displaying an evaluation result of the data processing unit so as to check whether the boiler tube is damaged or not.

In the boiler state monitoring apparatus according to the present invention, the acoustic sensor unit may include a microphone mounting device for mounting the microphone in a hole formed in an outer wall of the boiler.

In the boiler state monitoring apparatus according to the present invention, the microphone mounting device may include: a rectangular parallelepiped housing having an internal space in which the microphone is disposed; A connection pipe having one end connected to one side surface of the housing and the other end opposite to the one end passing through the hole and disposed inside the boiler; A microphone cable which is inserted into the inside of the unidirectional other side of the housing and connected to the microphone; An air purge line connected to a portion of the connection pipe and injecting air into the boiler through the connection pipe; And a power cable installed with the microphone cable and extending through one longitudinal side of the housing and connected to the air purge line.

In the boiler state monitoring apparatus according to the present invention, the microphone mounting device may further include a cooling device installed in the housing to prevent damage to the microphone due to high temperature transmitted from the boiler to the microphone.

In the boiler state monitoring apparatus according to the present invention, the sound quality evaluation of the data processing unit may include at least one of loudness, negative sharpness, negative roughness, and negative octave components You can evaluate more than one.

According to the present invention, sound quality evaluation is performed on the noise of a boiler input through a microphone, so that it is possible to accurately determine whether or not the boiler facility, that is, the tube is damaged.

Particularly, when the boiler state monitoring apparatus according to the present invention is used, abnormalities are detected in negative or negative color when an abnormality occurs in the boiler tube, which is completely different from the magnitude of the sound pressure, By analyzing, it is possible to judge whether or not the tube is broken at the early stage of the breakage of the boiler tube.

In addition, leakage of the boiler tube is gradually progressed until the boiler stops, while affecting other tube leaks after the initial generation. In the past, when the degree of tube breakage becomes worse or the boiler itself can not be operated, However, when the boiler state monitoring apparatus according to the present invention is used, the leakage of the tubes can be continuously detected, and the progress of the tube leak can be grasped. Therefore, it is possible to carry out stable boiler operation Management can be done.

1 is a block diagram for explaining a boiler state monitoring apparatus according to the present invention;
FIG. 2 and FIG. 3 are photographs for explaining a microphone mounting device of a boiler state monitoring apparatus according to the present invention.
4 is a photograph showing a data acquisition and calculation board of the boiler state monitoring apparatus according to the present invention.
5 is a photograph for explaining an example of sound quality evaluation of the boiler state monitoring apparatus according to the present invention.
6A to 6C are photographs for explaining the evaluation of sound strength in Fig. 5; Fig.
7A to 7C are photographs for explaining the evaluation of the sound sharpness in Fig. 5; Fig.
FIG. 8 is a photograph for explaining an example of a boiler convention through sound quality evaluation of the boiler state monitoring apparatus according to the present invention. FIG.

BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments described herein but may be embodied in other forms. Rather, the embodiments disclosed herein are provided so that the disclosure may be thorough and complete, and will fully convey the concept of the invention to those skilled in the art.

And, when an element is referred to herein as being on another element, it may be directly formed on another element or it may mean that a third element may be interposed therebetween.

Also, where the terms first and second are used herein to describe components, these components should not be limited by such terms. These terms are merely used to distinguish one element from another. Further, when it is mentioned that the first component is operated or executed on the second component, the first component may be operated or executed in an environment where the second component is operated or executed, or may be directly or indirectly It should be understood that it is operated or executed through interaction.

Furthermore, the terms used herein are intended to be illustrative of the embodiments but not to limit the invention, and the singular forms herein may include plural forms, unless the context clearly dictates otherwise. That is, 'comprises' and / or 'comprising', as used herein, means that the recited element does not exclude the presence or addition of one or more other elements.

Also, in the drawings, the shapes and thicknesses of components and the like may be exaggerated in order to emphasize a clearer description, and the same members in the drawings are denoted by the same reference numerals. It is to be noted that, in the description of the invention, it is commonly known that portions not related to the invention are not described in order to prevent confusion in explaining the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a block diagram for explaining a boiler state monitoring apparatus according to the present invention, and FIGS. 2 and 3 are photographs for explaining a microphone placing apparatus of a boiler state detecting apparatus according to the present invention.

1, a boiler state monitoring apparatus 100 according to the present invention includes a sound sensor unit 10, a signal converting unit 20, a data processing unit 30, and a display unit 40.

For example, the acoustic sensor unit 10 may include a microphone, and the acoustic sensor unit 10 including a microphone may be formed by drilling an outer wall of the boiler, And a microphone mounting device in which a microphone is built in an outer wall of the boiler including the hole.

2 and 3, a microphone mounting device 50 according to the present invention includes a housing 52, a connection pipe 54, a microphone 56, a microphone cable 58a, a power cable 58b, And an air purge line 58c. In addition, the microphone mounting device 50 may further include a cooling device, for example, an air-cooled fan (not shown).

The housing 52 may have a generally rectangular parallelepiped shape and may have an internal space in which the microphone 56 may be disposed. Alternatively, the housing 52 may have various shapes other than a rectangular parallelepiped shape in a range having an inner space.

3, the housing 52 is shown as an open structure. However, in reality, when the microphone 56 is housed while the microphone 56 is housed, the external noise is prevented from entering the microphone 56, It can be understood that it is sealed so as not to be damaged.

One end of the connecting pipe 54 is connected to one side of the housing 52 and the other end of the connecting pipe 54 passes through a hole formed in the outer wall of the boiler, Respectively. Such a connection tube 54 may be provided in the form of a generally elongated cylindrical tube, or alternatively it may be provided in the form of an elongated polygonal tube.

Although the connection pipe 54 is not shown in detail in the state where the other end thereof is located inside the boiler passing through a hole provided in the outer wall of the boiler, it may be completely joined with the outer wall surface of the boiler by welding or the like from the boiler outer wall, Accordingly, the gap between the outer wall surface of the boiler and the connection pipe 54 is eliminated, so that the internal noise of the boiler can be collected reliably through the microphone 58.

Here, the complete connection between the outer wall surface of the boiler and the connection portion 54 can be realized through the formation of a sealing material instead of welding. One end of the connecting pipe 54 may be completely joined to one unidirectional side of the housing 52 by welding or the like. At this time, the one end of the connecting pipe 54 is connected to one end of the housing 52, The one side of the connecting pipe 54 and the one side of the housing 52 can be mutually penetrated.

Meanwhile, the connection pipe 54 of the present invention is installed at an angle of 10 to 30 DEG C with respect to the outer wall surface of the boiler, so that the noise trapping inside the boiler can be more reliably performed.

The microphone 56 is for collecting noise inside the boiler, and its configuration can be understood to be the same as or similar to that normally used for collecting sound, and detailed description and description thereof will be omitted in the present embodiment do. The microphone 58 is located in the housing 52 and various structures for mounting the microphone 56 may be installed inside the housing 52. [ For example, in the present embodiment, an interlayer may be provided inside the housing 52 for mounting the microphone 60.

One end of the microphone cable 58a is connected to a data acquisition board (not shown) and the other end of the microphone cable 58a is connected to one longitudinal side of the housing 52 from the outside of the housing 52, And is connected to the microphone 56. At this time, it is preferable that the microphone cable 58a is made of a material which can withstand the high temperature coming from the boiler.

The power cable 58b is inserted into the housing 52 together with the microphone cable 58a and then passes through the unidirectional other side surface of the housing 52 facing the installation surface of the connection pipe 54, And the extended power cable 58b is connected to the appropriate position of the air purge line 58c for injecting air into the boiler, for example, the electronic valve as shown in FIG. It is preferable that the power cable 58B is also made of a material that can withstand the high temperature coming from the boiler.

The air purge line 58c is provided to maintain the connection of the connection pipe 54 due to the sludge generated in the boiler and the cleanliness of the sensor. The air purge line 58c is connected to the connection pipe 54 And the other end is connected to the electronic valve. At this time, an air spray nozzle (not shown) may be installed at the connection portion with the connection pipe 54.

Therefore, the air purge line 58c ejects air to the connection pipe 54 through the electromagnetic valve to automatically remove the sludge accumulated in the connection pipe 54 at a predetermined time or manually, And sensor contamination can be prevented.

The cooling device (not shown) is provided to prevent the microphone 56 from being damaged by the heat of high temperature transmitted from the boiler. Although not shown, the cooling device is preferably installed adjacent to the microphone 56, , Air-cooled fan.

As described above, the microphone mounting device 50 of the present invention is provided to measure the internal noise of the boiler even at a high temperature. That is, according to the present invention, it is possible to prevent a high temperature of 70 ° C or more from being transmitted to the microphone 56 through the installation of the microphone mounting device 50, thereby causing damage to the microphone 56 due to high temperature, And solves the problem that the collection of the internal noise is not performed properly.

In detail, the inside of the boiler has a property of a vacuum relative to the outside of the boiler due to the high temperature. Therefore, the heat inside the boiler tends to be introduced into the boiler due to the pressure difference, rather than being transmitted to the outside. However, the radiant heat inside the boiler is transmitted to the outside. ) Can be sufficiently damaged.

However, according to the present invention, by providing a small-sized hole having a diameter of 10 mm or less on the outer wall of the boiler and providing a microphone mounting device 50 having a microphone 56 built therein, Noise can be captured. In other words, according to the present invention, a small diameter hole is drilled in the inspection hole of the outer wall of the boiler, and a microphone mounting device 50 is installed thereon. In addition, even if the heat of high temperature inside the boiler escapes to reach the microphone, It is possible to prevent damage to the microphone 56 by operating a cooling device such as an air-cooled fan provided in the device 50. [

The cables 58a and 58b connected to the housing 52 in which the microphone 56 is housed are also made of materials that can withstand high temperature heat and are used to protect the cable. (Not shown) can be used to minimize damage to the cables 58a, 58b.

On the other hand, in the case of the present invention, the line work is performed in the controlled area where the heat inside the boiler is not transferred during the wiring work, thereby also preventing the worker's damage due to the high temperature heat.

1, the signal conversion unit 20 in the boiler state monitoring apparatus 100 according to the present invention converts the noise in the boiler collected through the acoustic sensor unit 10 into a digital signal . The signal conversion unit 20 includes a first circuit that can convert sound into an acoustic signal and a second circuit that converts the sound signal into a digital signal that can process data, And may further include various unit circuits and semiconductor elements necessary for the entire circuit configuration.

The data processing unit 30 evaluates the sound quality from the noise converted into the digital signal by the signal converting unit 20.

For example, in the embodiment of the present invention, the sound quality evaluation of the data processing unit 30 may include at least one of negative loudness, negative sharpness, negative roughness, and negative band components Or by evaluating one or more of them.

<< Features and related expressions of sound quality components >> Sound quality component Characteristic Related formulas

Negative Strength
( Loudness)
Display the strength of the sound the person feels
There is a clear difference in the degree of human perception compared to the sound pressure level (SPL).

N ': Special Loudness
z: Critical Band



Sharpness of sound
(Sharpness)


Sharpness of sound
The higher the frequency, the stronger the intensity.

g '(z): Weighting Function
Negative roughness
(Roughness)
Representing the roughness of the sound
It is a factor that can be used to know the clarity of the sound. R = Cal · Fmod · ΔL
Cal: Calibration Factor
Fmod: Frequency of modulation
ΔL: Perceived masking depth


Negative band
(Octave)

A method of classifying sounds according to frequency band

In other words, the present invention evaluates at least one of the four sound quality components using software for the noise collected from the boiler, as shown in Table 1 above, so that the abnormality of the boiler tube can be detected very early . That is, the present invention compares the steady state and the abnormal state using each software for each of the four components constituting sound quality to determine whether or not the boiler tube is abnormal.

To this end, the data processing unit 30 of the present invention may include a dedicated data acquisition and calculation board 100 as shown in FIG. Here, although the data acquisition and calculation board 100 is not clearly shown, a power source card, a main controller card, and a signal acquisition and calculation card may be configured in a slot shape. The data acquisition and calculation board 100 has a backboard between the function card on the front side and the terminal module on the rear side, and each card is connected through the backboard.

Meanwhile, in the case of the data acquisition and calculation board 100 according to the present invention, the stability can be improved by the redundancy of the power supply unit and the main control unit, and a separate device other than the monitoring PC is required I do not. That is, in the present invention, since the FFT (Fast Fourier Transform) function is embedded in the signal acquisition card, only the final result value is transmitted to the display unit 40, for example, the monitoring PC, so that a separate device is not required. In addition, each card can store its own data for 48 hours, so there is no loss of data even if there is a problem with the monitoring PC. Each card can improve the resolution and bandwidth by using 24 bit 192Ksps AD converter . In addition, each functional slot is capable of arbitrarily mounting required cards.

The display unit 40 is provided to display the evaluation result of the data processing unit 30 and may be, for example, a monitoring PC. The display unit 40, which is configured by a monitoring PC, The user will be able to view the evaluation results of the four sound quality components so that the user can view the sound quality components displayed on the display unit 40, i.e., the sound intensity, the sharpness of sound, the roughness of sound, By visually checking the state, it is possible to check whether or not leaks of the boiler tube, that is, the breakage of the boiler tube, can be confirmed.

5 is a photograph for explaining an example of sound quality evaluation of the boiler state monitoring apparatus according to the present invention.

First, the noise of the boiler collected from the acoustic sensor unit is converted into a digital signal by the signal conversion unit, and then the sound quality is evaluated using software in a data processing unit based on the noise. The result is displayed on a display unit 40).

In FIG. 5, the upper left graph is a graph relating to a negative band (Octave), the lower left graph is a graph relating to loudness, and the upper right graph is a graph relating to negative sharpness And the graph on the lower right side is a graph relating to the negative roughness (roughness).

As a special boiler sound, the parameters of loudness and negative sharpness can be used to monitor boiler sound. In particular, among these two parameters, the intensity of the negative is more pronounced than the sharpness of the negative. The intensity of the sound allows the operator to easily identify the state of the boiler in the current situation through the chart line.

FIGS. 6A to 6C are graphs for explaining the evaluation of the sound intensity for analyzing the state of the boiler sound.

Referring to FIG. 6A, when the steady-state boiler sounds from the steady state graph, the negative intensity graph line A shown at 8-15Bark is drawn at a position lower than the low frequency. This means that the frequency of the normal sound contains more factors than it does for the low frequencies, and it does not sound as noisy as a cracking sound.

On the other hand, referring to FIG. 6B, it can be seen from the tube leakage state graph that the high frequency of the negative intensity graph line A is much larger than the steady state. In other words, the line graph of the intensity of sound in 15 ~ 20Bark is larger than that in 8 ~ 15Bark. This is due to the fact that more noise is present in the higher frequency domain. Also, the sound sounds very rough than normal.

Accordingly, as shown in FIG. 6C, when the negative intensity graphs of the steady state and the leakage state are overlapped, it is possible to easily distinguish the tube leakage state state from the normal state state. Here, the frequency band of all signals may not be equal to all of the compared values, but it is possible to determine an abnormal state by changing a specific frequency domain as shown in FIG. 6C.

7A to 7C are photographs for explaining a negative sharpness evaluation for analyzing the state of the boiler sound,

Sound sharpness is one of the parameters that can monitor boiler sound. Although not as clear as the intensity of the sound, it is a very useful parameter, and Figs. 7a and 7b show steady state and tube leakage conditions with respect to negative sharpness.

Here, based on the calculation method of the negative sharpness, if the sound is very sharp and sharp, the value of the negative sharpness will become very large. On the other hand, if the sound feels very dull, the sharpness of the note will be very small and zero. Thus, when the boiler is in a steady state, the negative sharpness graph B is drawn as in FIG. 7A, while the graph B is drawn lower than the tube leakage condition in FIG. 7B. However, the sharpness value of the sound shows the same tendency for the sound.

Therefore, as shown in FIG. 7C, when the negative sharpness graphs of the steady state and the leakage state are overlapped, when the tube leakage occurs, the high frequency of the failed signal is higher than the normal signal.

As described above, according to the present invention, only one of the sound quality components can be selected, or all four components can be selected, and the presence or absence of a steady state and an anomaly state can be confirmed for each component through data that is higher than standard data in each graph.

In addition, the present invention sets the data obtained by measuring the steady-state boiler sound for a predetermined period as standard data, and sets the management band automatically by setting the period and data at this time. Here, the data graph obtained by the data processing unit is more than 10% higher than the standard data, and is managed as "Caution" when it occurs for a certain period of time. And manage it.

For example, the yellow line in FIG. 8 is a primary warning line, and when the signal is out of 5%, a primary warning occurs, and then the boiler state should be carefully monitored.

A flashing line indicates a secondary path, signal is off by 10%, and other measures are necessary to indicate an abnormality in the boiler's condition.

As a result, in the present invention, the noise inherent in the boiler generated in the boiler is collected by the microphone of the acoustic sensor unit, and the thus-collected noise is converted into a digital signal that can be analyzed by the signal conversion unit, (Intensity, roughness, sharpness, and band) of the steady state are continuously monitored by monitoring the sound quality changes when the sound quality is changed, by judging whether the boiler tube is abnormal or not .

Particularly, since the present invention can detect minute changes in sound, it is possible to perform tracking control from the time of occurrence of leakage of the boiler tube, early alarm is possible, and the progress of the boiler tube leak can be grasped Of course, it is possible to minimize the planned maintenance and management losses and to ensure stable boiler operation and management.

While the present invention has been particularly shown and described with reference to specific embodiments thereof, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, It will be readily apparent to those skilled in the art that the present invention can be modified and changed without departing from the scope of the present invention.

10: Acoustic sensor unit 20: Signal conversion unit
30: data processing section 40: display section
50: microphone mounting device 52: housing
54: connector 56: microphone
58a: Microphone cable 58b: Power cable
58c: air purge line 100: data acquisition and calculation board

Claims (5)

A boiler condition monitoring system for evaluating the sound quality from the noise inside the boiler to evaluate the quality of the boiler,
An acoustic sensor part installed through the hole from the outer wall of the boiler and collecting noise inside the boiler;
A signal converter for converting the sound signal collected by the sound sensor unit into a digital signal suitable for sound quality evaluation;
A data processor for evaluating the sound quality of the noise from the noise converted into the digital signal by the signal converter; And
A display unit for displaying an evaluation result of the data processing unit so as to check whether the boiler tube is broken or not;
A boiler condition monitoring system based on sound quality evaluation.
The sound sensor unit according to claim 1,
And a microphone mounting device for mounting the microphone in a hole formed in an outer wall of the boiler, the microphone mounting device including a microphone.
3. The microphone mounting device according to claim 2, wherein the microphone mounting device
A rectangular parallelepiped housing having an inner space in which the microphones are disposed;
A connection pipe having one end connected to one side surface of the housing and the other end opposite to the one end passing through the hole and disposed inside the boiler;
A microphone cable which is inserted into the inside of the unidirectional other side of the housing from the outside and connected to the microphone;
An air purge line connected to a portion of the connection pipe and injecting air into the boiler through the connection pipe; And
A power cable installed together with the microphone cable and extending through one longitudinal side of the housing and connected to the air purge line;
The boiler state monitoring apparatus comprising:
The portable telephone according to claim 1, wherein the microphone mounting device
Further comprising a cooling device installed inside the housing to prevent damage to the microphone due to a high temperature that is transmitted from the boiler to the microphone.

The method of claim 1, wherein the quality evaluation in the data processing unit
Wherein at least one of the negative loudness, the negative sharpness, the negative roughness and the negative octave components is evaluated.

Images