Abstract:
A pulverizer  10  includes a journal assembly  19  with a grinding roller  18  that grinds solids in a grinding table  14 . The oscillations of the journal assembly  19  are monitored by an angular displacement transducer (ADT)  32  that creates a composite signal. A controller  83  receives the composite signal from the ADT and compares it with known information of the pulverizer  10 . It then identifies abnormal situations such as damage to a grinding roll  14 , the grinding table  14 , the spring assembly  20  and other parts of the pulverizer  10  before they cause major damage.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional of U.S. patent application Ser. No. 14/068,136, having a filing date of Oct. 31, 2013, which is a divisional of U.S. patent application Ser. No. 12/951,172, having a filing date of Nov. 22, 2010, issued on Dec. 10, 2013 as U.S. Pat. No. 8,602,338, which are incorporated by reference herein in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to solid fuel pulverizers and is more particularly directed to the measurement of angular displacement of journal assemblies and their attached grinding rolls within solid fuel pulverizers. 
       BACKGROUND 
       [0003]    Solid fossil fuels such as coal often are ground in order to render the solid fossil fuel suitable for certain applications. Grinding the solid fossil fuel can be accomplished using a device referred to by those skilled in the art as a pulverizer. One type of pulverizer suited for grinding is referred to as a “bowl mill pulverizer”  10  as shown in  FIG. 1 . This type of pulverizer obtains its name by virtue of the fact that the pulverization that takes place on a grinding table  14  that resemblance to a bowl. 
         [0004]    The bowl mill pulverizer  10  includes a substantially closed separator body  12 . A grinding table  14  is mounted on a shaft  16 . A motor and gearbox drive mechanism (not shown) rotate the grinding table  14 . These components arranged within the separator body  12 . 
         [0005]    A plurality of journal assemblies  19  and grinding rolls  18 , preferably three, are supported within the separator body  12  so as to be equidistantly spaced one from another around the circumference of the separator body  12 . Only one journal assembly  19  and grinding roll  18  of three is shown in  FIG. 1 . Each of the grinding rolls  18  is supported and rotates on a suitable shaft (not shown) of a journal assembly  19 . The journal assemblies  19  and grinding rolls  18  are allowed to pivot away from the grinding table  14  by the trunnion shaft  36 . 
         [0006]    Each of the grinding rolls  18  has a spring assembly  20  acting on the journal head  70  of the journal assembly  19 . Each of the spring assemblies  20  applies a spring load on the corresponding grinding roll  18  causing them to pivot on trunnion shaft  36  and to exert the requisite degree of force on the solid fuel on the grinding table  14  pulverizing the solid fuel into powder. 
         [0007]    The solid fuel is provided through fuel inlet tube  22  and falls through to grinding table  14  to be pulverized. 
         [0008]    After being pulverized, the particles of the solid fuel are thrown outwardly by centrifugal force, whereby the particles are fed into a stream of warm air and blown into a classifier  30  for separation by particle size. The particles of the proper size are passed out of outlets  34 . 
         [0009]    The larger particles fall downward through outlet  28  for more grinding. The greater the force, the finer the particle size of the fossil fuels being ground. 
         [0010]    There are devices which provide feedback regarding the amount of force being applied to each grinding roll  18  as described in U.S. patent application Ser. No. 12/490,668 filed Jun. 24, 2010 “Force Monitor For Pulverizer Integral Spring Assembly”. This does not however, indicate angular displacement of the trunnion shafts  36  and journal assemblies  19 . 
         [0011]    The forces acting on the journal assembly  19  are the spring force, which forces the journal assembly downward, and the reaction force of the grinding roll upon the solid fuel bed contained on the grinding table  14 , which forces the journal assembly upward and downward, creating the oscillations. There are normal oscillations that occur within an acceptable range, however, there are also abnormal oscillations indicating a problem with the pulverizer. 
         [0012]    The force measured by load cells do not directly relate to the displacement of the journal assemblies  19 . This is because the forces provided by the springs typically do not have a linear relationship with displacement. 
         [0013]    The linear change in the spring is related to many thousands of pounds of force. Therefore, it is not very accurate in measuring small forces that have small angular displacements. 
         [0014]    Also, the force v. displacement curve exhibited by a spring changes over time as the spring ages. 
         [0015]    Due to the non-linear relationship between displacement and force and the fact that springs change their displacement vs. force curve for several reasons, monitoring linear spring displacement relating to oscillations can be inaccurate. 
         [0016]    The information that is currently available on conventional pulverizers is the initial spring force (initial spring compression) which is set on each journal spring assembly prior to the pulverizer being placed into service and the initial clearance set between the grinding roll  18  and grinding table  14  (the “roll-ring clearance”). 
         [0017]    For journal assemblies  19  of shallow bowl type pulverizers, an additional piece of known information is the clearance between a journal head  70  and the seat of the spring assembly  20 . However, the accuracy by which each of these items is set is dependent on the skill of the workers, the accuracy of the equipment and gages used by the workers, and the method the worker use to perform the work. 
         [0018]    Presently, there is little or no instrumentation present to measure these oscillations. The journal assemblies  19  are currently evaluated visually by watching the end face of the trunnion shaft  36  and comparing its movement to the vibration of the bowl mill pulverizer  10 . 
         [0019]    This is a crude method and the ability to obtain useful results from it is highly dependent on the experience of the personnel who perform it. 
         [0020]    The result is that operation problems or failure of the pulverizer, its grinding components, or its gearbox components can occur before the conditions responsible for creating the problems are noticed and corrected. 
         [0021]    Currently, there is a need for feedback to more accurately monitor various abnormalities of a pulverizer. 
       SUMMARY 
       [0022]    According to aspects disclosed herein, the invention may bee embodied as a pulverizer  10  for pulverizing a solid fuel, the pulverizer  10  having a pulverizer housing having a shaft coupled for rotation therein, a grinding table  14  rotatably mounted on the shaft, at least one journal assembly  19  pivotally mounted on the pulverizer housing, a grinding roll  18  coupled to the at least one journal assembly  19 , a spring assembly  20  is mounted on the pulverizer housing, wherein the spring assembly  20  urging the grinding roll  18  toward the grinding table  14 ; and an angular displacement transducer (ADT)  32  coupled to the journal assembly  19  adapted to measure angular displacement of at least one journal assembly  19  and create an electronic signal corresponding to the measured angular displacement. 
         [0023]    The invention may also be embodied as a method of identifying potential problems of a pulverizer  10 . The method includes the steps of acquiring angular displacement signal of at least one journal assembly  19  over time, and indicating that there is a potential problem with the pulverizer  10  when the angular displacement signal is an abnormal signal. 
         [0024]    The abnormal signal may be a signal that exceeds a maximum or minimum angular displacement, or has an average angular displacement greater than a predetermined threshold 
         [0025]    The invention may also be embodied as a device for measuring the operation of at least one journal assembly  19  pivoting on a trunnion shaft  36  of a pulverizer  10  having an angular displacement transducer (ADT) adapted to measure the degree of rotation of a shaft, a coupling  3  attached between the trunnion shaft and having a shaft connected to the ADT for transmitting rotation of the trunnion shaft to the ADT thereby causing the ADT to constantly measure the trunnion shaft  36  rotation, a controller  83  coupled to the ADT for reading the measured rotation and for identifying abnormal operation conditions. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    Referring now to the figures, which are exemplary embodiments, and wherein like elements are numbered alike: 
           [0027]      FIG. 1  is a perspective view of a bowl mill pulverizer showing the journal assembly, grinding roll, spring assembly and rotating grinding table. 
           [0028]      FIG. 2  is an enlarged, cross-sectional view of the bowl mill pulverizer of  FIG. 1  including the having an angular transducer according to the present invention. 
           [0029]      FIG. 3  is an enlarged view of one embodiment of an oscillation monitor according to the present invention. 
           [0030]      FIG. 4  is a side elevational view of a pressure retaining-type coupling adapter  4  according to one embodiment of the present invention. 
           [0031]      FIG. 5  is a cross section of  FIG. 4  as view from the lines marked “5-5”. 
           [0032]      FIG. 6  is a cross section of  FIG. 4  as view from the lines marked “6-6”. 
           [0033]      FIG. 7  is a side elevational view of a suction-type coupling adapter  4  according to one embodiment of the present invention. 
           [0034]      FIG. 8  is a cross section of  FIG. 7  as view from the lines marked “8-8”. 
           [0035]      FIG. 9  is a cross section of  FIG. 4  as view from the lines marked “9-9”. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Magnitude 
         [0037]    Referring again to  FIG. 1 , during operation of a bowl mill pulverizer  10 , the forces that act on each journal assembly  19  cause it to oscillate continuously in the upward and downward direction, rotating around a trunnion shaft  36 . Oscillations having a magnitude within a normal range are acceptable. Oscillations having a magnitude outside of a normal range can indicate problems with the bowl mill pulverizer  10 . 
       Frequency 
       [0038]    Measuring the oscillation of a journal assembly  19  over time will result in a complex oscillation signal comprised of multiple overlaid frequencies. There are also several (usually three) journal assemblies  19  that are monitored, providing these signals. Proper analysis of these signals alone, or in combination will provide indications of problems occurring in the bowl mill pulverizer  10 . 
       Phase 
       [0039]    Even if two identical journal assemblies  19  were to react exactly the same and produce the same signal under the same conditions, the signals of each would be 120 degrees our of phase (in an equally spaced three-journal bowl mill pulverizer  10 ). 
         [0040]    If the oscillation signals from the journal assemblies  19  were properly acquired, they could be correlated with known information regarding the geometry and functioning to identify problems that exist with pulverizer  10 . Therefore, signals may be identified that indicate one or more potential problems occurring within the pulverizer  10 , before major damage occurs. 
         [0041]    A prior art load cell of a conventional pulverizer only measures positive, or pushing forces of the spring assembly as described in U.S. patent application Ser. No. 12/490,668 above. There are no measurements of the actual journal assembly movement (oscillation) as the forces of the spring assembly and coal bed are applied to it. 
       Equal Oscillation 
       [0042]    Unequal oscillation among the journal assemblies  19  creates a variable loading of the grinding and gearbox components of the pulverizer  10 . It also creates reaction forces transmitted back to the journal assemblies  10 . 
         [0043]    It is important that all journal assemblies oscillate equally in order to:
       a. prevent bending and failure of the pulverizer gearbox components,   b. provide the necessary coal fineness for efficient boiler operation, boiler combustion and emissions control.       
 
         [0046]    The present invention monitors angular displacement (oscillation angle) over time for each journal assembly  19 . These signals are processed to determine an overall running maximum/minimum amplitude (oscillation range), maximum amplitude for a defined period of time and repeated patterns (oscillation rate). These are correlated with the frequency of grinding table  14  rotation, and grinding roll  18  rotation. These are then used to identify problems within the pulverizer. 
         [0047]      FIG. 2  shows an embodiment of a journal assembly compatible with the present invention. For ease of illustration, only one journal assembly  19  and associated spring assembly  20  are shown and described, but the invention is not limited in this regard, and in other embodiments the pulverizer  10  may comprise two, three, or more journal assemblies and associated spring assemblies, which may be evenly distributed about the grinding table  14 . 
         [0048]    The journal assembly  19  carries grinding roll  18  rotatably mounted thereon and positions the grinding roll to define a gap G 1  between the grinding roll and the grinding table  14 . The gap G 1  varies when the journal assembly  19  pivots on the trunnion shaft  36 . Optionally, the journal assembly  19  may be configured so that there is a gap G 2  between the journal head  78  and the spring assembly  20 . The gap G 2  is at a maximum when the journal assembly pivots fully forward, i.e., when the gap G 1  is at a minimum. 
         [0049]    An angular transducer  32  is attached to the journal assembly, near the trunnion shaft  36 . It monitors the angular (rotation) about the trunnion shaft  36 . This effectively measures the oscillations of journal assembly  19  over time. 
         [0050]    The signals from the angular transducer  32  are conveyed via the output lead  2  to a controller  83  (e.g., suitable data monitor and recording equipment, a programmable logic controller and/or a suitably programmed general purpose computer) that may optionally be positioned in a control room for observation and analysis by a user. In addition, the signal from the output lead  36  enables the user to measure, record and display the angular movement (oscillation) of journal assembly  68  over time during operation of the pulverizer  10 . 
         [0051]    In conventional pulverizers, the result is that operational problems or failure of the pulverizer, its grinding components, or its gearbox components can occur before the condition responsible for creating the problem is noticed and repaired or corrected. In the present invention, the signal from the angular transducer  32  is monitored to provide early detection of abnormalities. This data will permit the real time detection, analysis and correction of problems with the pulverizer  60  mechanical components and performance during operation. 
         [0052]    The installation of an oscillation monitor  32  onto each journal assembly  19  of the pulverizer  10  will enable the oscillation rate, oscillation range, oscillation angle, and rate of change of the angular displacement of each journal assembly during operation to be displayed, monitored and recorded at the pulverizer and in the control room of a power plant. 
         [0053]    The process signal may be used to detect several different abnormal conditions, as described below. 
         [0054]    1. Improper Initial Clearance Set Between the Grinding Roll  18  and Grinding Table  14  (the Roll/Ring Setting Procedure) 
         [0055]    The oscillation signal from one journal assembly  19  is consistently higher, on the average, than the others. 
         [0056]    2. Improper Depth of the Coal Bed on the Bowl 
         [0057]    More than one journal assembly  19  indicates continuous average angular deflections that are above (or below) a predetermined threshold. 
         [0058]    3. Weakening, Damage or Fatigue of the Journal Spring Assembly  20   
         [0059]    This will be indicated by greater maximum and minimum oscillations as compare with the other journal assemblies  19 . 
         [0060]    4. Increased Wear and Location of Wear on the Grinding Roll 
         [0061]    Small continuous oscillations from a single journal assembly  19  indicating a rough grinding roll surface such as caused by its surface being broken apart. 
         [0062]    A periodic local minimum oscillation with a period equal to the circumference of a grinding roll is sensed, indicating a flat side to the grinding roll. 
         [0063]    The phase of the signal will indicate where the flat location is on the grinding roll. 
         [0064]    5. Decreased Roundness (Circularity) of the Grinding Roll 
         [0065]    A repeated periodic signal with a period of the grinding roll circumference will be sensed. 
         [0066]    6. Increased Wear and Location of Wear on the Bowl Grinding Table 
         [0067]    Small continuous oscillations from a single journal assembly  19  indicating a rough grinding table  14  surface. 
         [0068]    7. A Cracked or Warped Grinding Table  14   
         [0069]    A quick angular rate of change at a one or more points in the signal with a pattern that repeats with a period equal to the grinding table  14  rotation indicated a cracked grinding table  14 . A warped grinding table will have a smooth characteristic periodic wave with a period equal to that of the rotating grinding table  14 . 
         [0070]    8. Debris/Rocks on the Grinding Table  14   
         [0071]    A signal similar to a cracked grinding table  14  is indicated, if the debris is attached to the grinding table  14 . 
         [0072]    A quick rate of angular change at random points in the signal with no periodic pattern will be sensed if the rocks are not attached to the grinding table  14 . 
       Implementation 
       [0073]      FIG. 3  shows the present invention as it will be installed on a pulverizer  10 . This is a partial cut-away view showing the trunnion shaft  36  extending horizontally. The trunnion shaft  36  extends through the trunnion shaft end cap  7 . It is then attached to a coupling adapter  4  that may be a pressure retaining type adaptor or may be a suction type adapter. 
         [0074]    A coupling  3  attaches the angular transducer  32  to the coupling adapter  4 . A mounting bracket  5  supports the added parts. 
         [0075]    The signal from the angular transducer  32  is passed through a signal cable  2  to a controller  83  that drives a local display  85  mounted on, or near the pulverizer ( 10 ). The controller will operate at least one remote display  87  located in a control room  90 , or other areas of the plant. The controller  83  reads the signal provided to it and provides early warnings on local display  85  and remote display(s)  87  when the monitored signals indicate a malfunction. The controller  83  also provides monitoring information of the normal operation of the pulverizer  10 . 
         [0076]    1) The following parts are required to retrofit an existing bowl mill pulverizer: an angular displacement transducer  32 , a signal cable  2  a coupling  3 , a coupling adapter  4  and a mounting bracket  5 . The remaining parts are the standard ones of the journal assembly  19 . 
         [0077]    This arrangement enables all movement of the trunnion shaft  6  to be transmitted directly into the angular displacement transducer  32 . 
         [0078]    2) The angular displacement transducer  1  is installed onto the journal assembly  8  by locating it on one side of the trunnion shaft  36 . The body of the angular displacement transducer  32  is fastened to a mounting bracket  5  that is either fastened to the journal opening cover, the trunnion shaft end cap  7 , or another stationary part of the pulverizer, the journal assembly (B), or the work deck. The mounting bracket  5  holds the body of the angular displacement transducer  1  stationary during operation. 
         [0079]    When Pulverizer is the pressurized type (RPS, RP &amp; HP) on which a pressurized seal air system is used, the angular displacement transducer  32  is installed on the opposite side of the journal assembly  19  where a seal air hose connects to the trunnion shaft  36 . 
         [0080]    When Pulverizer is a suction type (RB &amp; RS), the angular displacement transducer ( 1 ) can be installed on either side of the journal assembly  8 . 
         [0081]    3) In  FIG. 3 , the angular displacement transducer  32  has a rotating input shaft  33  that extends from its body. The rotating input shaft  33  is fastened tight to one end of the coupling  3  by use of a mechanical connection arranged to eliminate all lost motion. The other end of the coupling  3  connects to the coupling adapter  4  and is held tightly to it using a mechanical connection to eliminate all lost motion. 
         [0082]    4) The coupling  3  is arranged to transmit all motion that enters into it and to eliminate all lost motion. The coupling  3  can be either a rigid type or the flexible type. 
         [0083]    The use of flexible coupling  3  will enable the angular displacement transducer  32  to be mounted off center (not in alignment with the trunnion shaft  36  center line) without loss of rotational motion. This enables the angular displacement transducer  32  to be installed in locations where access space is restricted. 
         [0084]    5) The coupling adapter  4  is fastened rigidly to the trunnion shaft  36 . It is arranged to transmit all angular motion that it experiences. 
         [0085]    The attachment of the coupling adapter  4  to the trunnion shaft  36  can be by the following methods: 
         [0086]    a) by threading it into the trunnion shaft bore using the existing NPT pipe thread within the bore, 
         [0087]    b) by welding it to the trunnion shaft, or 
         [0088]    c) by bolting it using new holes drilled and tapped into the trunnion shaft. 
         [0089]    When Pulverizer is the shallow bowl pressurized type (RPS, RP &amp; HP) the coupling 
         [0090]    adapter  4  is arranged to prevent the escape of the pressurized seal air from the trunnion shaft  36 . 
         [0091]    When Pulverizer is the shallow bowl suction type (RS), the coupling adapter  4  is arranged with air passages within it to allow atmospheric air from the work deck to enter into the trunnion shaft  36  as seal air. 
         [0092]    When pulverizer is the deep bowl suction type (RB), no provision for seal air is required in the coupling adapter  4 . 
         [0093]    6) The signal cable  2  is located on the body of the angular displacement transducer  32 . 
         [0094]    The signal cable  2  supplies the input power to the angular displacement transducer  32  and returns the output signal from it for processing. The signal cable  2  is the flexible, high temperature resistant, shielded type to prevent failure from grease, vibration, and high temperature at the pulverizer and the work deck that surrounds the pulverizer. The signal cable  2  is equipped with quick-disconnect fittings to speed assembly to and removal from the angular displacement transducer  32  and the adjoining system wiring. 
         [0095]    7) The output signal from the angular displacement transducer  32  is displayed and recorded in the control room for observation and analysis by use of suitable data monitoring and recording equipment. 
         [0096]    The signal is processed to show the oscillation rate, oscillation range, and oscillation angle that occur on each journal assembly  19  of the pulverizer. 
         [0097]    The basic unit of the data obtained for the display is “degrees of rotation”. This is used because it is applicable to all types and sizes of journal assemblies. 
         [0098]    The processed signals will permit the real time detection, analysis and correction of problems with the pulverizer mechanical components and performance during operation. 
         [0099]    In addition, the present invention provides the following advantages over conventional systems:
       Plant safety can be improved by providing real time detection and analysis of the signal from the angular transducer  32 , which can provide early indications of several types of mechanical and operation problems in a pulverizer  10 .   It will simplify the work required to equalize the adjustment and setting of each journal assembly  19  and spring assembly  20  in order to reduce the imbalance forces that act on the gearbox components. This, in turn, will extend the service life of the gearbox components.   The design simplifies and improves the accuracy of the adjustment process of the journal assemblies  19 , and the spring assemblies  20  and other devices on the pulverizer  10  to maintain the required coal fineness necessary for proper combustion and emissions control.   It can be installed without having to obtain access to or modify any of the spring assembly  20  components.   It is easily removed, and the majority of the components can be replaced during operation without having to remove the pulverizer from service.   The data collected is not affected by the clearance between the journal head  70  and pressure spring seat of the spring assembly  20 . In addition, the design will show if the clearances between the journal head  70  and pressure spring seat are not set equally.   The angle in degrees of rotation is measured that makes the system applicable to all types and sizes of journal assemblies  19  because it does not require conversion to account for the different designs of journal assemblies  19 .       
 
         [0107]      FIGS. 4, 5 and 6  show a pressure retaining-type embodiment of coupling adapter  4  compatible with the present invention that uses pressurized seal air to stop coal dust from building up journal oil seals and bearings. 
         [0108]      FIG. 4  is a side elevational view of the pressure retaining-type coupling adapter  4 . The coupling adapter  4  has a threaded shaft  43  extending from a body  41 . A pressure-retaining type of adapter stops the pressurized seal air flowing through the center opening in the trunnion shaft ( 36  of  FIGS. 1-3 ) from leaking out. Therefore, the threaded shaft  43  threads into the trunnion shaft ( 36  of  FIGS. 1-3 ) in a manner that prevents seal air leakage. 
         [0109]      FIG. 5  is a cross section of  FIG. 4  as view from the lines marked “5-5”. Here a cross section of a solid shaft  45  is shown. This shaft  45  connects to the coupling ( 3  of  FIG. 3 ) and transmits any rotation of shaft  45  to the coupling. 
         [0110]      FIG. 6  is a cross section of  FIG. 4  as view from the lines marked “6-6”. Here, a solid square cross-section of the body  41  of coupling adapter  4  is shown. 
         [0111]      FIGS. 7, 8 and 9  show a suction-type coupling adapter  4  embodiment compatible with the present invention that uses air suction to stop coal dust from building up journal oil seals and bearings. 
         [0112]      FIG. 7  is a side elevational view of a suction-type coupling adapter  4  showing a threaded shaft  53  extending from a body  51 . A suction-type of adapter  4  allows ambient air to enter and flow through a center opening in the trunnion shaft ( 36  of  FIGS. 1-3 ). The threaded shaft  43  with a central air duct  59  that threads into the trunnion shaft ( 36  of  FIGS. 1-3 ). 
         [0113]    Body  51  also has side air ducts  57  that are in fluid communication with central air duct  59 . Suction from inside of the pulverizer draws ambient air in through the side ducts  57  of body  51 , through central duct  57  on through the central opening of trunnion shaft ( 36  of  FIGS. 1-3 ). 
         [0114]      FIG. 8  is a cross section of  FIG. 7  as view from the lines marked “8-8”. Here a cross section of a solid shaft  55  is shown. This shaft  55  connects to the coupling ( 3  of  FIG. 3 ) and transmits any rotation of shaft  55  to the coupling. 
         [0115]      FIG. 9  is a cross section of  FIG. 4  as view from the lines marked “9-9”. Here a solid square cross-section of the body  51  of the coupling adapter  4  is shown. 
         [0116]    While the invention has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.