Furnace structural integrity monitoring systems and methods
First Claim
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1. An acoustic emission monitoring system for monitoring structural integrity of a furnace having a furnace shell, the system comprising:
- a controller; and
a plurality of acoustic emission sensors mounted to the furnace shell and in communication with the controller to provide electric signals corresponding to one or more acoustic emissions generated in the furnace to the controller, the plurality of acoustic emission sensors comprising at least three acoustic emission sensors, wherein at least two acoustic emission sensors are vertically offset from each other and at least two acoustic emission sensors are laterally offset from each other, and wherein the vertical offset is smaller than the lateral offset, and wherein an electric signal is registered as an acoustic emission event if detected by a predetermined number of acoustic emission sensors,wherein the controller is configured to determine an operating threshold value during steady-state operation of the furnace and determine one or more failure conditions based on the operating threshold value and one or more acoustic emission events,wherein the controller includes a location module for estimating a location of origin of the one or more failure conditions, andwherein the controller is configured to analyze a moment tensor determined by the controller based on one or more electric signals pertaining to a particular acoustic emission event in order to identify a cracking mode associated with the particular acoustic emission event.
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Abstract
Various systems and method for acoustic monitoring of smelting furnaces and similar devices are disclosed. Acoustic sensors (and optionally other sensors) are mounted to the furnace. Acoustic emission events generated in the furnace are analyzed to identify conditions that exceed one or more thresholds. The location of acoustic emissions may be identified and reported. Output signals may be generated in response to acoustic emissions. The location of acoustic emissions may be used to identify the location of potential failures in the furnace.
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Citations
29 Claims
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1. An acoustic emission monitoring system for monitoring structural integrity of a furnace having a furnace shell, the system comprising:
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a controller; and a plurality of acoustic emission sensors mounted to the furnace shell and in communication with the controller to provide electric signals corresponding to one or more acoustic emissions generated in the furnace to the controller, the plurality of acoustic emission sensors comprising at least three acoustic emission sensors, wherein at least two acoustic emission sensors are vertically offset from each other and at least two acoustic emission sensors are laterally offset from each other, and wherein the vertical offset is smaller than the lateral offset, and wherein an electric signal is registered as an acoustic emission event if detected by a predetermined number of acoustic emission sensors, wherein the controller is configured to determine an operating threshold value during steady-state operation of the furnace and determine one or more failure conditions based on the operating threshold value and one or more acoustic emission events, wherein the controller includes a location module for estimating a location of origin of the one or more failure conditions, and wherein the controller is configured to analyze a moment tensor determined by the controller based on one or more electric signals pertaining to a particular acoustic emission event in order to identify a cracking mode associated with the particular acoustic emission event. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method of monitoring the structure of a furnace having a furnace shell, the method comprising:
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mounting a plurality of acoustic emission sensors to the furnace shell, wherein the plurality of acoustic emission sensors comprise at least three acoustic emission sensors, wherein at least two acoustic emission sensors are vertically offset from each other and at least two acoustic emission sensors are laterally offset from each other, and wherein the vertical offset is smaller than the lateral offset, and wherein an electric signal is registered as an acoustic emission event if detected by a predetermined number of acoustic emission sensors; providing a controller coupled to the plurality of acoustic emission sensors; receiving, by the controller, from the plurality of acoustic emissions sensors, electric signals corresponding to one or more acoustic emissions generated in the furnace, wherein an electric signal is registered as an acoustic emission event if detected by a predetermined number of acoustic emission sensors; determining, by the controller, an operating threshold value during steady-state operation of the furnace; determining, by the controller, one or more failure conditions based on the operating threshold value and one or more acoustic emission events; analyzing, by the controller, the electric signals for estimating a location of origin of the one or more failure conditions; and analyzing a moment tensor based on one or more electric signals pertaining to a particular acoustic emission event in order to identify a cracking mode associated with the particular acoustic emission event. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29)
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Specification