Description:
Field of the Invention:
[001] The present invention relates to the field of industrial safety and monitoring systems, specifically to an automated tube leakage detection and alarm system designed for use in high-pressure boilers within power plants. More particularly, the invention pertains to a compact, cost-effective solution that integrates sensors, audio signal processing, and control mechanisms to detect, monitor, and alert operators to potential tube leaks. The system is designed to improve safety, reduce downtime, and enhance operational efficiency, especially for smaller power plants that face space and budget constraints. It involves advanced technology for real-time detection, alarm activation, and automated responses to mitigate risks associated with tube leaks in high-pressure environments.
Background of the invention and related prior Art:
[002] In high-pressure boilers used in power plants, tube leaks pose significant safety risks, including the potential for catastrophic failures, system downtime, and costly repairs. Traditional methods for detecting tube leaks are often manual, labor-intensive, and prone to delays, making it difficult to quickly identify and address issues before they escalate. Additionally, many smaller power plants face financial and space constraints, limiting their ability to invest in large, expensive leak detection systems. Existing solutions are typically costly and require extensive sensor setups and large control panels, making them unaffordable or impractical for smaller-scale operations. There is a growing need for a more compact, affordable, and automated solution that can efficiently detect leaks, provide real-time alerts, and ensure timely interventions to prevent damage. This invention addresses these challenges by offering a compact, cost-effective tube leakage detection system that retains all necessary functionalities while being easily accessible to smaller plants, improving safety and operational reliability.
[003] In a patent document JPH05296869A discloses an alarm of abnormal leakage, a determination of a leakage position and a measure such as an instruction of avoidance action according to a degree of leakage by obtaining a plurality of pieces of informa tion on liquid leakage from various detection means.
[004] A document CN103456120A relates to a double-gas-line type temperature sensing fire detector and a detection method of the double-gas-line type temperature sensing fire detector. The double-gas-line type temperature sensing fire detector comprises a box body and multiple detection pipelines outside the box body. The detection pipelines comprise detection outer pipes and detection inner pipes located in the detection outer pipes. First detection gases are filled into the detection outer pipes. Second detection gases are filled into the detection inner pipes. Expansion coefficients of the first detection gases and the second detection gases are different. The detection pipelines are provided with first ends and second ends which correspond to the first ends. Pressure sensors used for measuring values of outer pipe gas pressure in the detection outer pipes and values of inner pipe gas pressure in the detection inner pipes are arranged in the box body. The output ends of the pressure sensors are connected with a central processor. The output end of the central processor is electrically connected with an alarm outputting circuit. The double-gas-line type temperature sensing fire detector and the detection method of the double-gas-line type temperature sensing fire detector are simple in structure, high in detection precision, high in automation degree, wide in application range, safe and reliable.
[005] Another document CN111828845A discloses an artificial intelligence based automatic pipeline leakage detection method which comprises the steps of obtaining historical initial data collected by a pipeline sensor, marking the historical initial data, collecting initial measurement data of a pressure pump, a safety valve and a liquid filling pipe, calculating the current pressure value of a pipeline according to the initial measurement data and the historical initial data, calculating the final pressure value of the pipeline, fitting the periodic motion of the pressure pump, calculating the real pressure value of the pipeline, outputting a data track tracking expected value by adopting an artificial intelligence model, and judging whether the pipeline leaks or not. The invention utilizes the existing sensor in the pipeline system to detect the leakage, does not need to purchase redundant expensive professional equipment, combines an artificial intelligence model, and utilizes the simulation result training detector to detect whether the leakage occurs, thereby greatly reducing a large amount of manpower and capital cost spent on the leakage detection and having strong operability.
[006] In a document JP2021103184A relates generally to the detection of leaks in pressurized systems, and more specifically to the detection of aperiodic leaks using pressure sensing.
[007] Another patent document US20190234786A1 discloses a water meter and leak detection system that has a private or public property(ies) facility water supply interruption system. The system is comprised of a water meter collection node system with shut-off/on mechanism that has wireless Bluetooth, Bluetooth low energy, Zigbee, Z-wave LoRa, Wi-Fi, radio frequency and cellular technology with a private or corporate network, or internet connection that transfer water parameter data to a remote computer or server. Or the system can consist of a water meter collection node that communicates by Bluetooth, Bluetooth low energy, Zigbee, Z-wave LoRa, Wi-Fi, radio frequency and cellular technology with a data communication hub whereby the communication hub is in wired or wireless communication with an internet router that communicates with an internet connection, or with a private or commercial network system, to a remote computer/server or a cloud-computing commercial service.
[008] None of these above patents, however alone or in combination, disclose the present invention. The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
Summary of the Invention:
[009] The present invention provides a compact, automated system for detecting tube leaks in high-pressure boilers, designed to improve safety and efficiency in power plants, particularly for smaller-scale operations. The system integrates sensors that detect the acoustic signals associated with leaks, a preamplifier to amplify and filter the sound, and an industrial PC equipped with SCADA software to monitor and analyze the data. When a leak is detected, the system activates an alarm to alert the operator and can trigger corrective actions, such as activating a purge operation through a relay module. The entire system is housed in a space-efficient 19-inch 3U sub rack, making it affordable and easy to install in plants with limited space. By offering a cost-effective solution that retains all necessary functionalities of larger systems, this invention ensures timely leak detection, enhances safety, and reduces operational risks without the need for extensive infrastructure or high upfront costs.
Detailed Description of the Invention with Accompanying Drawings:
[010] For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its preparation, and many of its advantages should be readily understood and appreciated.
[011] The principal object of the invention is to develop compact automated tube leakage detection and alarm system for high-pressure boilers. The invention relates to a compact and automated tube leakage detection and alarm system designed for use in high-pressure boilers in power plants. It provides an efficient and cost-effective solution to detect tube leaks, monitor system performance, and alert operators to potential hazards. The system integrates multiple components working in tandem to ensure real-time leak detection and prompt response actions. Below is a detailed description of the key components and how they function together:
1. Sensor (Leak Detection):
The sensor plays a pivotal role in the system by detecting the specific acoustic signals emitted when a tube leaks. The sensor is sensitive to the sound frequencies associated with the leak (typically within a range of 2 kHz to 8 kHz) and converts the detected sound into an electrical signal. This signal is then transmitted to the preamplifier for further processing. The sensor is strategically placed within the environment to ensure accurate detection of any leakage noise.
2. Preamplifier:
The preamplifier receives the audio signal from the sensor and performs two critical functions: amplification and filtering. The preamplifier amplifies the weak signal from the sensor to a level suitable for further processing. It also filters the audio signal, passing only the frequencies within the 2 kHz to 8 kHz range, which are most relevant for detecting tube leaks. This ensures that only the pertinent signals are sent forward for analysis, eliminating unnecessary noise and improving detection accuracy.

3. ASLD Micro Module:
The filtered and amplified audio signal is sent to the ASLD (Automated Sound Leak Detection) micro module. This module analyzes the incoming audio signals and determines if the characteristics match those typically associated with tube leaks. If the system identifies a potential leak based on the sound pattern, it triggers the necessary actions to alert the operator.
4. Industrial PC with SCADA Software (ASLD):
The Industrial PC is the central processing unit of the system. It runs ASLD SCADA (Supervisory Control and Data Acquisition) software that monitors the entire leak detection system. The PC is connected to a monitor, which acts as the Human-Machine Interface (HMI), allowing operators to view real-time data and status updates of the system. Through this interface, operators can issue commands to control various system functions. The PC also processes the signals from the ASLD micro module and determines whether the audio signal indicates a leak that exceeds a predefined decibel threshold. If the leak signal reaches a certain level, the PC triggers the alarm system and any necessary automated responses.
5. Relay Module and Solenoid Valve Control:
The relay module interfaces with the controller and is used to operate solenoid valves, particularly to initiate a purge operation when a leak is detected. Upon receiving a command from the Industrial PC, the relay module activates the solenoid valve to execute the purge operation, which helps mitigate the effects of the leak and prevents further system damage. Additionally, the relay module provides potential-free contacts to signal leak alarms and system faults, ensuring that operators are informed of critical issues.
6. Alarm System:
The alarm system is triggered whenever a leak is detected. The system generates both visual and audible alarms to inform the operator of the detected leak. The visual alarms can include flashing lights, and the audible alarm can include a siren or alert tone, ensuring the operator is aware of the issue, even if they are not actively monitoring the system. The alarm alerts the operator to take corrective actions as needed, helping to prevent further damage and reduce the risk of accidents.

7. Compact and Cost-Effective Design:
The entire system is housed in a compact 19-inch 3U sub rack, making it significantly smaller and more space-efficient than traditional leak detection systems, which often require large control panels and numerous sensors. This compact design makes it an affordable solution, especially for smaller power plants with limited space and budget. Despite its smaller size, the system retains all the necessary features to ensure accurate leak detection, real-time monitoring, and timely responses.
8. System Integration and Operation:
When the sensor detects a potential leak, the system amplifies and filters the audio signal, processes it through the preamplifier and ASLD micro module, and sends it to the Industrial PC for analysis. If the audio signal exceeds the threshold indicating a leak, the system triggers the alarm and activates the appropriate actions, such as the purge operation via the relay module. The operator is alerted through both the alarm system and the HMI, allowing for immediate intervention to mitigate the risk.
[012] This invention provides a highly effective and affordable automated solution for detecting tube leaks in high-pressure boilers, addressing the challenges faced by smaller power plants. The compact design, integrated components, and real-time monitoring ensure the system operates efficiently, providing timely alerts and minimizing the risk of damage or failure due to tube leaks.
Figure 1. ASLD micro system according to the embodiment of the present invention.
Figure 2. Working mechanism according to the embodiment of the present invention.
Figure 3. ASLD micro module according to the embodiment of the present invention.
[013] Without further elaboration, the foregoing will so fully illustrate my invention, that others may, by applying current of future knowledge, readily adapt the same for use under various conditions of service. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention.
Advantages over the prior art
[014] Compact automated tube leakage detection and alarm system for high-pressure boilers proposed by the present invention has the following advantages over the prior art:
1.Compact and Space-Efficient Design:
The system is housed in a 19-inch 3U sub rack, making it significantly smaller and more space-efficient than traditional leak detection systems, which require large panels and complex setups. This compact design allows the system to be easily installed in smaller power plants with limited space.
2. Cost-Effective Solution:
The invention provides an affordable alternative to conventional leak detection systems, which can be prohibitively expensive due to high sensor requirements, large infrastructure, and complex installation. The compact nature of the system reduces both initial investment and ongoing maintenance costs, making it accessible to smaller power plants with limited budgets.
3. Automated Leak Detection:
The system automatically detects leaks through sound analysis, removing the need for manual inspection and reducing human error. The integration of sensors, preamplifiers, and real-time processing ensures quick and accurate detection, enabling operators to respond promptly to potential leaks and prevent further damage.
4. Real-Time Monitoring and Alerts:
The system provides continuous real-time monitoring of the boiler's status, with audio signals and alarms promptly notifying the operator if a leak is detected. This helps operators act immediately to address the issue, reducing the likelihood of system failure or safety incidents.
5. Simplified Integration and Operation:
The system integrates various components such as sensors, preamplifiers, and the Industrial PC into a seamless operation, ensuring easy installation and user-friendly operation. The SCADA software provides an intuitive Human-Machine Interface (HMI), allowing operators to monitor and control the system with minimal training.
6. Enhanced Safety and Risk Mitigation:
By detecting tube leaks at an early stage, the system helps mitigate the risk of catastrophic failures, explosions, or boiler malfunctions, which can result in significant downtime, repairs, and safety hazards. The real-time alarm system ensures that operators can take immediate action to prevent further damage.

7. Efficient Space Utilization:
The compact system design allows it to be mounted on walls or placed on tables, making it versatile for plants with limited floor space. This feature is especially valuable for smaller plants or those operating in tight physical environments.
[015] In the preceding specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
, Claims:We claim:
1. A tube leakage detection system for high-pressure boilers, comprising:
- a sensor configured to detect an acoustic signal corresponding to a tube leak,
- a preamplifier to amplify and filter the acoustic signal, passing only frequencies between 2 kHz and 8 kHz,
- an ASLD micro module configured to analyze the amplified and filtered signal and determine the presence of a tube leak, and
- an industrial PC running SCADA software, the PC receiving the analyzed signal and generating a leak alarm if the signal exceeds a predefined threshold.
2. The system of claim 1, further comprising a relay module that operates a solenoid valve to initiate a purge operation upon detection of a leak, wherein the relay module also provides potential-free contacts for leak and system fault alarms.
3. The system of claim 1, wherein the sensor is an audio sensor capable of detecting the frequency range associated with the sound generated by a tube leak.
4. The system of claim 1, wherein the preamplifier is configured to amplify the signal from the sensor and filter out frequencies outside the 2 kHz to 8 kHz range to improve detection accuracy.
5. The system of claim 1, wherein the industrial PC further includes a Human-Machine Interface (HMI) displayed on a monitor, allowing the operator to interact with the system and issue commands to control system functions based on leak detection data.
6. The system of claim 1, wherein the leak alarm includes both audible and visual indicators, such as flashing lights and sound, to ensure that the operator is notified of the detected leak.
7. A method for detecting tube leaks in high-pressure boilers, comprising the steps of:
- receiving an acoustic signal from a sensor detecting a tube leak sound,
- amplifying and filtering the signal in a preamplifier to pass frequencies within the 2 kHz to 8 kHz range,
- analyzing the amplified and filtered signal in an ASLD micro module to determine whether the signal indicates a leak,
- generating a leak alarm if the signal exceeds a predefined threshold, and
- triggering a purge operation via a relay module and solenoid valve if a leak is confirmed.
8. The method of claim 7, wherein the leak alarm is triggered by the industrial PC, which uses SCADA software to monitor the signal and alert the operator if a leak is detected.
9. The system of claim 1, wherein the entire system is housed within a compact 19-inch 3U sub rack, allowing for easy installation and operation in plants with limited space.
10. The system of claim 1, wherein the system is cost-effective and suitable for small-scale power plants, reducing the need for expensive, large-scale leak detection systems typically used in larger plants.