Concept Development of a Vibration Sensor for Industrial Boilers

Abstract

An acoustic horn has been developed for Sasol Synfuels in Secunda. It has been concluded that this is the best methodology for dislodging ash agglomeration on the boiler tubes, since it can perform this act while boilers are in operation, thereby eliminating the need to shut down boilers for cleaning. The acoustic horn utilises sound energy that induces vibration and strain on the boiler substructure components. This results in a concern to develop vibration and strain sensors in order to measure these phenomena. An accelerometer is considered to monitor vibration signals, while a secondary strain-gauge sensor is considered to measure strain signals. The analysis entails a predetermined assessment of the suitable sensor parameters for the anticipated input signals. The appropriate accelerometer for this kind of application is concluded to be a piezoelectric accelerometer with a sensitivity of 1000 mV/G as most suitable. Furthermore, a strain-gauge sensor of a quarter-bridge type one with a gauge factor of 2 and nominal resistance of 350 Ω is deemed to be most suitable.