Note: Descriptions are shown in the official language in which they were submitted.
CA 02697124 2010-03-18
233083-1
SLAG ZONE MAPPING
BACKGROUND OF THE INVENTION
The subject matter disclosed herein relates to solutions for mapping slag
zones in a
boiler. Specifically, the subject matter disclosed herein relates to mapping
slag zones
in fossil-fuel fired boiler systems.
Fossil-fuel fired boiler systems are commonly used to generate electricity.
One type
of fossil-fuel fired boiler system combusts an air/coal mixture to generate
heat energy.
This heat energy is used to increase a temperature of water to produce steam.
This
steam is then used to drive a turbine generator that outputs electrical power.
These fossil-fuel fired boiler systems may have regions in which slag or
unburned
hydrocarbons adhere to walls of the boiler system and accumulate to form large
masses. If this slag formation is not controlled, the accumulation may affect
run-time
efficiency of the boiler system, as well as the maintenance cycle.
BRIEF DESCRIPTION OF THE INVENTION
Solutions for mapping slag zones in a boiler are disclosed. In one embodiment,
the
slag zone mapping system includes: an obtainer for obtaining data about a
location of
a slag zone within a boiler, the slag zone being one of a plurality of slag
zones in a
slag plane; a determinater for determining a flow distribution of a working
fluid
within the boiler, the flow distribution originating at a plurality of burners
and
intersecting the slag zone and a sensor grid including a plurality of grid
sensors; an
identifier for identifying at least one grid sensor in the plurality of grid
sensors that is
intersected by the flow distribution of the working fluid; and a user
interface module
for displaying the flow distribution of the working fluid from the plurality
of burners
to the at least one grid sensor.
-1-
CA 02697124 2010-03-18
233083-1
A first aspect of the invention provides a slag zone mapping system
comprising: an
obtainer for obtaining data about a location of a slag zone within a boiler,
the slag
zone being one of a plurality of slag zones in a slag plane; a determinater
for
determining a flow distribution of a working fluid within the boiler, the flow
distribution originating at a plurality of burners and intersecting the slag
zone and a
sensor grid including a plurality of grid sensors; an identifier for
identifying at least
one grid sensor in the plurality of grid sensors that is intersected by the
flow
distribution of the working fluid; and a user interface module for displaying
the flow
distribution of the working fluid from the plurality of burners to the at
least one grid
sensor.
A second aspect of the invention provides a boiler comprising: a plurality of
burners;
a working fluid heated by the plurality of burners; a sensor grid in contact
with the
working fluid; and a slag zone mapping system connected to the sensor grid and
the
plurality of burners, the slag zone mapping system including: an obtainer for
obtaining data about a location of a slag zone within a boiler, the slag zone
being one
of a plurality of slag zones in a slag plane; a determinater for determining a
flow
distribution of a working fluid within the boiler, the flow distribution
originating at a
plurality of burners and intersecting the slag zone and a sensor grid
including a
plurality of grid sensors; an identifier for identifying at least one grid
sensor in the
plurality of grid sensors that is intersected by the flow distribution of the
working
fluid; and a user interface module for displaying the flow distribution of the
working
fluid from the plurality of burners to the at least one grid sensor.
A third aspect of the invention provides a program product stored on a
computer
readable medium, which when executed, performs the following: obtaining data
about
a location of a slag zone within a boiler, the slag zone being one of a
plurality of slag
zones in a slag plane; determining a flow distribution of a working fluid
within the
boiler, the flow distribution originating at a plurality of burners and
intersecting the
slag zone and a sensor grid including a plurality of grid sensors; identifying
at least
one grid sensor in the plurality of sensors that is intersected by the flow
distribution of
the working fluid; and displaying, on a user interface, the flow distribution
of the
working fluid from the plurality of burners to the at least one grid sensor.
-2-
CA 02697124 2010-03-18
233083-1
A fourth aspect of the invention provides a method of generating a system for
mapping slag zones in a boiler, the method comprising: providing a computer
system
operable to: obtain data about a location of a slag zone within the boiler,
the slag zone
being one of a plurality of slag zones in a slag plane; determine a flow
distribution of
a working fluid within the boiler, the flow distribution originating at a
plurality of
burners and intersecting the slag zone and a sensor grid including a plurality
of grid
sensors; identify at least one grid sensor in the plurality of grid sensors
that is
intersected by the flow distribution of the working fluid; and display, on a
user
interface, the flow distribution of the working fluid from the plurality of
burners to the
at least one grid sensor.
A fifth aspect of the invention provides a method comprising: at least one of
providing or receiving a copy of a computer program that is embodied in a set
of data
signals, wherein the computer program enables a computer system to implement a
method of mapping slag zones in a boiler, the method comprising: obtaining
data
about a location of a slag zone within the boiler, the slag zone being one of
a plurality
of slag zones in a slag plane; determining a flow distribution of a working
fluid within
the boiler, the flow distribution originating at a plurality of burners and
intersecting
the slag zone and a sensor grid including a plurality of grid sensors;
identifying at
least one grid sensor in the plurality of grid sensors that is intersected by
the flow
distribution of the working fluid; and displaying, on a user interface, the
flow
distribution of the working fluid from the plurality of burners to the at
least one grid
sensor.
A sixth aspect of the invention provides a method of mapping slag zones in a
boiler,
the method comprising: obtaining data about a location of a slag zone within
the
boiler, the slag zone being one of a plurality of slag zones in a slag plane;
determining
a flow distribution of a working fluid within the boiler, the flow
distribution
originating at a plurality of burners and intersecting the slag zone and a
sensor grid
including a plurality of grid sensors; identifying at least one grid sensor in
the
plurality of grid sensors that is intersected by the flow distribution of the
working
fluid; and displaying, on a user interface, the flow distribution of the
working fluid
from the plurality of burners to the at least one grid sensor.
-3-
CA 02697124 2010-03-18
233083-1
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of this invention will be more readily understood
from the
following detailed description of the various aspects of the invention taken
in
conjunction with the accompanying drawings that depict various embodiments of
the
invention, in which:
FIG. 1 shows a block diagram of an illustrative environment and computer
infrastructure for implementing one embodiment of the invention.
FIG. 2A shows a side cross-sectional view of a working fluid flow through a
boiler
according to one embodiment of the invention.
FIG. 2B shows a front view of a slag plane including a plurality of slag zones
according to one embodiment of the invention.
FIG. 3 shows a flow diagram of embodiments of mapping slag zones in a boiler.
FIG. 4 shows a screenshot of a graphical user interface according to one
embodiment
of the invention.
FIG. 5 shows a screenshot of a three-dimensional slag map according to one
embodiment of the invention.
It is noted that the drawings of the invention are not to scale. The drawings
are
intended to depict only typical aspects of the invention, and therefore should
not be
considered as limiting the scope of the invention. In the drawings, like
numbering
represents like elements between the drawings.
DETAILED DESCRIPTION OF THE INVENTION
As indicated above, aspects of the invention provide solutions for mapping
slag zones
in a boiler. As used herein, unless otherwise noted, the term "set" means one
or more
(i.e., at least one) and the phrase "any solution" means any now known or
later
developed solution.
-4-
CA 02697124 2010-03-18
233083-1
Turning to the drawings, FIG. 1 shows an illustrative environment 10 for
mapping a
slag zone in a boiler. To this extent, environment 10 includes a computer
system 20
that can perform a process described herein in order to map a slag zone in a
boiler. In
particular, computer system 20 is shown including a slag zone mapping system
30,
which makes computer system 20 operable to map slag in a boiler by performing
a
process described herein.
Computer system 20 is shown in communication with boiler 100, which may
include
slag sensors 34 and sensor grid 130. Further, computer system 20 is shown in
communication with user 36. A user may, for example, be a programmer or
operator.
Interactions between these components and computer system 20 will be discussed
in
subsequent portions of this application. Computer system 20 is shown including
a
processing component 22 (e.g., one or more processors), a storage component 24
(e.g., a storage hierarchy), an input/output (I/O) component 26 (e.g., one or
more I/O
interfaces and/or devices), and a communications pathway 28. In one
embodiment,
processing component 22 executes program code, such as slag zone mapping
system
30, which is at least partially embodied in storage component 24. While
executing
program code, processing component 22 can process data, which can result in
reading
and/or writing the data to/from storage component 24 and/or I/O component 26
for
further processing. Pathway 28 provides a communications link between each of
the
components in computer system 20. I/O component 26 can comprise one or more
human I/O devices or storage devices, which enable user 36 to interact with
computer
system 20 and/or one or more communications devices to enable user 36 to
communicate with computer system 20 using any type of communications link. To
this extent, slag zone mapping system 30 can manage a set of interfaces (e.g.,
graphical user interface(s), application program interface, and/or the like)
that enable
human and/or system interaction with slag zone mapping system 30.
In any event, computer system 20 can comprise one or more general purpose
computing articles of manufacture (e.g., computing devices) capable of
executing
program code installed thereon. As used herein, it is understood that "program
code"
means any collection of instructions, in any language, code or notation, that
cause a
computing device having an information processing capability to perform a
particular
-5-
CA 02697124 2010-03-18
233083-1
function either directly or after any combination of the following: (a)
conversion to
another language, code or notation; (b) reproduction in a different material
form;
and/or (c) decompression. To this extent, slag zone mapping system 30 can be
embodied as any combination of system software and/or application software. In
any
event, the technical effect of computer system 20 is to provide processing
instructions
for mapping slag zones in a boiler.
Further, slag zone mapping system 30 can be implemented using a set of modules
32.
In this case, a module 32 can enable computer system 20 to perform a set of
tasks
used by slag zone mapping system 30, and can be separately developed and/or
implemented apart from other portions of slag zone mapping system 30. Slag
zone
mapping system 30 may include modules 32 which comprise a specific use
machine/hardware and/or software. Regardless, it is understood that two or
more
modules, and/or systems may share some/all of their respective hardware and/or
software. Further, it is understood that some of the functionality discussed
herein may
not be implemented or additional functionality may be included as part of
computer
system 20.
When computer system 20 comprises multiple computing devices, each computing
device may have only a portion of slag zone mapping system 30 embodied thereon
(e.g., one or more modules 32). However, it is understood that computer system
20
and slag zone mapping system 30 are only representative of various possible
equivalent computer systems that may perform a process described herein. To
this
extent, in other embodiments, the functionality provided by computer system 20
and
slag zone mapping system 30 can be at least partially implemented by one or
more
computing devices that include any combination of general and/or specific
purpose
hardware with or without program code. In each embodiment, the hardware and
program code, if included, can be created using standard engineering and
programming techniques, respectively.
Regardless, when computer system 20 includes multiple computing devices, the
computing devices can communicate over any type of communications link.
Further,
while performing a process described herein, computer system 20 can
communicate
-6-
CA 02697124 2010-03-18
233083-1
with one or more other computer systems using any type of communications link.
In
either case, the communications link can comprise any combination of various
types
of wired and/or wireless links; comprise any combination of one or more types
of
networks; and/or utilize any combination of various types of transmission
techniques
and protocols.
As discussed herein, slag zone mapping system 30 enables computer system 20 to
provide processing instructions for mapping slag zones in a boiler. Slag zone
mapping system 30 may include logic, which may include the following
functions: an
obtainer 30, a determinater 50, an identifier 60 and a user interface 70
(FIG.2). In one
embodiment, slag zone mapping system 30 may include logic to perform the above-
stated functions. Structurally, the logic may take any of a variety of forms
such as a
field programmable gate array (FPGA), a microprocessor, a digital signal
processor,
an application specific integrated circuit (ASIC) or any other specific use
machine
structure capable of carrying out the functions described herein. Logic may
take any
of a variety of forms, such as software and/or hardware. However, for
illustrative
purposes, slag zone mapping system 30 and logic included therein will be
described
herein as a specific use machine. As will be understood from the description,
while
logic is illustrated as including each of the above-stated functions, not all
of the
functions are necessary according to the teachings of the invention as recited
in the
appended claims.
Turning to FIGS. 2A-2B, a cross-sectional view of a portion of a boiler 100
and a
front view of a slag plane 150 are shown, respectively. As used herein, boiler
100
refers to a portion of a fossil-fuel fired boiler, with portions omitted for
clarity. It is
understood that boiler 100 may not include all of the components present in a
fossil-
fuel fired boiler. FIG. 2A shows boiler 100 including a plurality of burners
110.
Plurality of burners 110 combust an air/coal mixture which generates heat
energy.
This heat energy may be used, for example, in increasing a temperature of
water to
produce steam, which may drive a steam turbine. Boiler 100 including plurality
of
burners 110 may be a part of a power generation system including, for example,
a
steam turbine and an electric generator (both omitted). In any event, boiler
100 may
combust the air/coal mixture producing a working fluid 120. Working fluid 120
-7-
CA 02697124 2010-03-18
233083-1
travels upward through boiler 100 due to its high temperature caused by
combustion.
Working fluid 120 may travel on a particular flow distribution upward through
boiler
100 due to conditions such as temperature, oxygen concentration, carbon
monoxide
concentration, flow rate, etc. Certain flow distributions, compositions of
working
fluid 120, and temperature conditions within boiler 100 may cause the build up
of
molten ash (slag) inside boiler 100. Slag may build up in a plurality of slag
zones 152
(FIG. 2B) within a slag plane 150. Slag plane 150 including plurality of slag
zones
152 are areas in which slag has begun to accumulate through the flow of
working
fluid 120. Slag may accumulate, for example through build-up on a boiler wall
160.
Molten ash (slag) particles may adhere to a portion of boiler wall 160,
thereby causing
a partial obstruction within boiler 100. Additional slag particles may adhere
to the
obstruction, causing a larger obstruction within boiler 100. Consequently,
over time,
the accumulation of slag may adversely affect performance of boiler 100.
The build-up of slag may be categorized by slag zones 152 within a slag plane
150.
Slag zones 152 may include locations within boiler 100 where slag has
accumulated
or where evaluation of slag is desired. Slag plane 150 may include observation
locations in one or more areas of boiler 100. In one embodiment, slag plane
150 may
be a vantage point for physical observation of a location of slag zone 152.
For
example, slag plane 150 may be located adjacent a door or opening on side 160
of
boiler 100. In this case, user 36 (FIG. 1) may look into an opening on wall
160 of
boiler 100 and physically observe a location of a slag zone 152. In another
embodiment, slag plane 150 may be set by the location of one or more slag
sensors 34
(FIG. 1) capable of measuring slag. Slag sensor(s) 34 may measure a flow rate
of
working fluid 120 at different portions of boiler 100. Further, slag sensor(s)
34 may
determine a temperature of working fluid 120 at different portions of boiler
100. Slag
sensor(s) 34 may also determine fluid concentrations (e.g., carbon monoxide)
and/or
other characteristics of working fluid 120 which may indicate the presence of
slag.
Also shown in FIG. 2A is a sensor grid 130, which may measure conditions of
working fluid 120 downstream (farther from plurality of burners 110) from slag
zone
152. Sensor grid 130 may include a plurality of sensors (not shown). The
plurality of
sensors may measure carbon monoxide (CO) concentrations, mass/volume flow
rates,
-8-
CA 02697124 2010-03-18
233083-1
and/or temperatures of working fluid 120. Further, this plurality of sensors
may
measure any parameter known to indicate formation of slag within working fluid
120.
Turning to FIG. 3, a flow diagram of embodiments of mapping slag zones in a
boiler
is shown. In step S1, obtainer 40 obtains data about a location of a slag zone
152
within the boiler. Slag zone 152 may be one of a plurality of slag zones 152
in slag
plane 150. Obtaining data may include observing the location of slag zone 152
through physical observation. As described with reference to FIG. 3, user 36
may
view a slag zone 152 through an opening, a door, or another vantage point in a
boiler
100. User 36 may enter data about a location of a slag zone 152 within a
boiler 100
into computer system 20 via a user interface (FIG. 4). The user interface of
one
embodiment of this invention will be discussed in further detail with
reference to FIG.
4. Alternatively, obtaining data about a location of a slag zone 152 may be
based on a
location of slag sensor(s) 34. Obtaining data using slag sensor(s) 34 is
described in
greater detail with reference to FIGS. 2A-2B. Slag sensor(s) 34 may be linked
to
computer system 20 in any conventional manner, and may provide data about a
location of a slag zone 152 within a boiler 100 in any conventional manner.
In step S2, determinater 50 determines a flow distribution of working fluid
120 within
boiler 100. The flow distribution originates at plurality of burners 110 and
intersects
slag zone 150 and sensor grid 130 including a plurality of grid sensors.
Determining
the flow distribution may be based on sensor grid data versus burner
conditions data
correspondence. This data correspondence may include data about conditions at
plurality of burners 110 and at sensor grid 130. These conditions may include:
air to
fuel ratios, CO concentrations, temperature, flow rates, etc.
Using the data correspondence and the data about a location of slag zone 152
within
boiler 100, identifier 60 may identify at least one grid sensor in the
plurality of grid
sensors in sensor grid 130 that is intersected by the flow distribution of
working fluid
120 in step S3. Each grid sensor within sensor grid 130 may have a data
correspondence with one or more specific burners 110 under predetermined
conditions. For example, plurality of burners 110 may produce a working fluid
120
that intersects sensor grid 130. Data correspondence between plurality of
burners 110
-9-
CA 02697124 2010-03-18
233083-1
and sensor grid 130 may indicate expected grid sensor readings (e.g.,
temperature, CO
concentration, etc.) for particular burner 110 conditions (e.g., temperature,
CO
concentration, etc.). However, slag zones 152 may interfere with the flow of
working
fluid 120 such that actual grid sensor readings at sensor grid 130 differ from
the
expected grid sensor readings. This discrepancy in grid sensor readings at
sensor grid
130 indicates a flow distribution of working fluid 120 which differs from an
expected
flow distribution. This different flow distribution can be traced to at least
one grid
sensor within sensor grid 130, and that at least one grid sensor can be
identified.
Based upon the location of slag zone 152, readings at sensor grid 130, known
conditions at plurality of burners 110 and sensor grid data versus burner
conditions
data correspondence, a flow distribution of working fluid 120 can be
determined.
In step S4, the method includes displaying the flow distribution of working
fluid 120
from plurality of burners 110 to the at least one sensor grid 130, for
example, on a
user interface 70. Turning to FIG. 4, user interface 70 is shown according to
one
embodiment of the invention. As illustrated, user interface 70 includes a
graphical
user interface. It is understood, however, that it may be embodied in many
different
forms, e.g., a numerical representation without graphics. In one embodiment,
user 36
may provide data about a location of a slag zone 152 within boiler 100 by
entering
data into user interface 70. User 36 may enter data into fields 72
representing slag
zones 152 within slag plane 150 of boiler 100. For example, fields 72 may
include a
plurality of settings, each indicative of an amount of slag present in a slag
zone 152.
In the illustrative example of FIG. 4, "L" indicates a default, or "no slag"
setting,
while "H" indicates the presence of slag. If user 36 determines slag plane 150
includes one or more slag zones 152, user 36 may indicate as much through
fields 72
of user interface 70. Alternatively, slag sensors 34 may provide data about a
location
of a slag zone 152 to slag zone mapping system 30. Slag zone mapping system 30
may then provide that data to user interface 70, which may indicate the
presence of
slag. User interface 70 may indicate the presence of slag, for example, by
indicating
an "H" in one or more of fields 72.
User interface 70 may also include sensor grid readings 74 that indicate
readings at
plurality of grid sensors on sensor grid 130. User interface may also include
boiler
-10-
CA 02697124 2010-03-18
233083-1
readings 76 as well as historical boiler data 78. Additionally, user interface
70 may
also include a "Calculate Slag Map" (CSM) button 80. User 36 may request
calculation of a slag map by triggering CSM button 80. Upon triggering of CSM
button 80, a boiler map 200 (FIG. 5) may be displayed in user interface 70, or
a
different user interface.
Turning to FIG. 5, a portion of an illustrative boiler map 200 is shown.
Boiler map
200 is a graphical representation of a flow distribution of working fluid 120
as
described with reference to FIGS. 1-3. Boiler map 200 may include a depiction
of
boiler 100, working fluid 120, and plurality of burners 110. In an alternative
embodiment, boiler map 200 may depict a slag plane 150, slag zones 152 and a
sensor
grid 130 as described with reference to boiler 100 in FIG. 2. Boiler map 200
may
indicate varying flow rates of working fluid 120 through different line
weights, styles,
or other emphasis/de-emphasis. Further, boiler map 200 may indicate varying
temperatures of working fluid 120 through line color, background/foreground
color,
labels, and/or segmenting. Boiler map 200 may also indicate differences in
conditions
within boiler 100 via any conventional means such as shading, highlighting,
animation, etc.. Boiler map 200 may indicate laminar flow conditions using
straight
or substantially straight lines. Additionally, boiler map 200 may indicate
various
turbulent flow conditions such as recirculation, eddies and apparent
randomness
through substantially curved lines and/or loops. Boiler map 200 may also
indicate
flow conditions by other conventional means, for example, labeling with text,
highlighting, shading, etc.
While shown and described herein as a slag zone mapping system, it is
understood
that aspects of the invention further provide various alternative embodiments.
For
example, in one embodiment, the invention provides a computer program embodied
in
at least one computer-readable medium, which when executed, enables a computer
system to map slag zones in a boiler. To this extent, the computer-readable
medium
includes program code, such as slag zone mapping system 30 (FIG. 1), which
implements some or all of a process described herein. It is understood that
the term
"computer-readable medium" comprises one or more of any type of tangible
medium
of expression capable of embodying a copy of the program code (e.g., a
physical
-11-
CA 02697124 2010-03-18
233083-1
embodiment). For example, the computer-readable medium can comprise: one or
more portable storage articles of manufacture; one or more memory/storage
components of a computing device; paper; and/or the like.
In another embodiment, the invention provides a method of providing a copy of
program code, such as slag zone mapping system 30 (FIG. 1), which implements
some or all of a process described herein. In this case, a computer system can
generate and transmit, for reception at a second, distinct location, a set of
data signals
that has one or more of its characteristics set and/or changed in such a
manner as to
encode a copy of the program code in the set of data signals. Similarly, an
embodiment of the invention provides a method of acquiring a copy of program
code
that implements some or all of a process described herein, which includes a
computer
system receiving the set of data signals described herein, and translating the
set of
data signals into a copy of the computer program embodied in at least one
computer-
readable medium. In either case, the set of data signals can be
transmitted/received
using any type of communications link.
In still another embodiment, the invention provides a method of generating a
system
for mapping slag zones in a boiler. In this case, a computer system, such as
computer
system 20 (FIG. 1), can be obtained (e.g., created, maintained, made
available, etc.)
and one or more modules for performing a process described herein can be
obtained
(e.g., created, purchased, used, modified, etc.) and deployed to the computer
system.
To this extent, the deployment can comprise one or more of: (1) installing
program
code on a computing device from a computer-readable medium; (2) adding one or
more computing and/or I/O devices to the computer system; and (3)
incorporating
and/or modifying the computer system to enable it to perform a process
described
herein.
It is understood that aspects of the invention can be implemented as part of a
business
method that performs a process described herein on a subscription,
advertising, and/or
fee basis. That is, a service provider could offer to provide processing
instructions for
mapping slag zones in a boiler as described herein. In this case, the service
provider
can manage (e.g., create, maintain, support, etc.) a computer system, such as
computer
-12-
CA 02697124 2010-03-18
233083-1
system 20 (FIG. 1), that performs a process described herein for one or more
customers. In return, the service provider can receive payment from the
customer(s)
under a subscription and/or fee agreement, receive payment from the sale of
advertising to one or more third parties, and/or the like.
This written description uses examples to disclose the invention, including
the best
mode, and also to enable any person skilled in the art to practice the
invention,
including making and using any devices or systems and performing any
incorporated
methods. The patentable scope of the invention is defined by the claims, and
may
include other examples that occur to those skilled in the art. Such other
examples are
intended to be within the scope of the claims if they have structural elements
that do
not differ from the literal language of the claims, or if they include
equivalent
structural elements with insubstantial differences from the literal languages
of the
claims.
-13-
