Background technology
Valve is in petroleum chemical industry performer key player, and according to statistics, the ethylene unit for producing 300,000 tons/year year is used
About 25000 various valves;The atmospheric and vacuum distillation unit of a set of 5000kt/a scales generally has the valve of 5000 or so
Door, the working condition of these valves decides product quality, and the unusual service condition such as interior leakage threatens equipment and personal security at any time,
And significant loss is easily caused, pollute environment.Statistics according to another external petroleum chemical enterprise in the eighties in last century, production dress
In putting there is different degrees of leakage in 5%~10% valve, the survey showed that 1%~2% valve produce leakage rate
But the always leakage about 70% or so of all valves is accounted for, further study show that in the valve or valve of flare system about 20%
Leakage valve can cause the economic loss of annual hundreds of thousands dollar in leakage, flare system 1, general according to certain domestic petrochemical plant valve
Come to an end fruit, and a valves leakage can cause the hydrocarbon gas of ten thousand stere to lose.
The desired value of reflection valve leak is the ability that each sealing position of its sealing, i.e. valve prevents dielectric leakage, and it is
The most important technical indicator of valve.The sealing position of valve has at 3:Contact position between opening and closing element and the sealing surface of valve seat two;Fill out
At the cooperation of material and valve rod and stuffing-box;The junction of valve body and bonnet.Valve is contacted between opening and closing element and the sealing surface of valve seat two
The leakage at place is referred to as to call interior leakage, that is, fits badly, and it directly affects the ability for blocking medium.For valve, interior leakage is not
Allow, its main function is exactly connection or closes fluid, interior leakage occur not only influences product quality, and seriously threatens
Safety and environmental protection, is one of the major reason of induction accident.The reason for for causing valves leakage, mainly have:(1) it is situated between
Matter is corroded, and sulfur-bearing, the gas medium containing acid corrode to sealing surface of the discharge gate in production process;(2) ageing equipment, petrochemical industry life
Production is that long period is continuously run, and long-term high-temperature high-pressure craft condition accelerates sealing surface of the discharge gate aging;(3) operate not
When, be frequently necessary to during petrochemical iy produced adjust some process section in valve switch, easily exerted oneself in operating valve lever
Not coaxial situation, causes sealing surface to destroy, manufacture in valve, transport, examine, install and use etc. during, also hold
Easily cause sealing face damage;(4) there is problem in product quality, the design and manufacturing process of valve, cause sealing surface to grind
Bad, sealing ring and valve seat, flap coordinate not tight, and flap is connected not firm etc. with valve rod, cause valve seal not sternly and
Cause dielectric leakage;(5) medium erosion, some media are gradually cooled down after valve closing, sealing surface thin seam is occurred,
Also erosion phenomenon can be produced, in addition, flow at high speed media impingement easily causes sealing face damage.
The patent of Application No. " CN201210319752.5 " discloses a kind of for the online of inflammable gas pipeline valve leak
Monitoring device and online test method, by installing combined valve on inflammable gas pipeline, are observed by the action of sleeving valve
Pressure change in pipeline, to determine the leakage situation of gas shut-off valve door and pipeline, can fast and accurately detect metallurgical work
Gas pipeline stop valve internal leakage in industry, is conducive to the raising production efficiency that guarantees safe production.However, this method needs
Combined valve is installed on inflammable gas pipeline, and needs to operate valve, in petrochemical industry, this method detection efficiency is low,
And the normal production of influence, do not possess application conditions.
The patent of Application No. " CN201010590565.1 " discloses a kind of detecting system leaked for gas valve, profit
Wireless pressure transmitter and the change of surface-mount type wireless temperature are installed with wireless sensor network disposition, including gas valve front and rear pipes
Device is sent, and wireless ultrasound leak sensor is installed in valve side, it is small from there through the pressure of section, temperature before and after valve
The detection of variable signal and ultrasonic signal wirelessly upload to computer, comprehensive utilization pressure distribution method, temperature inspection
Survey method, ultrasonic leak detection method are analyzed valve leak situation.This method degree of accuracy and sensitivity are higher, wireless pick-up
Device install convenient, it is not necessary to additionally lay signal cable, and can mending-leakage in time, there is weight to improving enterprises production efficiency
Big meaning.However, the problem of this method is present is, system complex, equipment cost is high, be not suitable for industrial production valve compared with
Many environment, also, for the less valve of diameter, small internal leakage, which is difficult to embody, arrives temperature, the change of pressure,
The influence of examined position of ultrasonic signal is larger, moreover, single-point acquiring ultrasonic signal is difficult to filter out the influence of man-made noise.
The patent of Application No. " CN201410569160.8 " is disclosed in a kind of gas valve based on Acoustic emission signal processing
Leak detection method, gathers signal first with acoustic emission sensor, by signal amplifier filtering process, obtains enhanced sound
Launching simulation signal, is converted to data signal by data collecting card and is sent to computer, computer records acoustic emission signal in real time
Root-mean-square value parameter;Successively using leakage analysis decision method in single-point method, two-point method, the collection of four-point method acoustic emission signal, lead to
Cross valves leakage acoustic emission signal root-mean-square value and judge that valve whether there is interior leakage.This method has stronger practicality, cost
Compare reasonable, detection efficiency height, do not influence normal production.However, this method is only capable of providing valve with the presence or absence of interior leakage
As a result, the result is affected by human factors larger, and can not further provide interior leakage degree.
At present, valves leakage, which is predominantly detected, depends on off-line checking method.For example, being stopped the Safety Inspection Summery-up Conference phase in device
Between, critical valves are disassembled, professional testing agency is sent to and carries out sealing propertytest, Main Basiss JB/T9092-1999,
The standards such as GB/T13927-1992, API598-2004 carry out intensity to various valves and sealing surface sealing property is examined,
Then body strength and sealing property test result are judged.This method does not require nothing more than harshness, it is necessary to which process units stops
Car, dismantles valve censorship, and detection efficiency is limited, and simply the hair valve at some critical process positions could receive detection,
The impossible censorship of most valves in whole technique, accordingly, there exist the phenomenon that substantial amounts of valves leakage is not detected in time.
With the development of science and technology, various non-destructive testing technologies are just progressively applied to petrochemical industry, wherein, acoustic emission has been considered as
The important technology direction of valves leakage on-line checking is solved, and there are relevant hardware devices completely to gather valves leakage sound hair
Signal is penetrated, the whether interior leakage of valve is judged according to personal experience.However, this method is easily influenceed by personal experience, knot is judged
The multifactor impacts such as fruit equipment performance, use environment, use condition, user of service, and it is difficult to the amount that provides interior leakage degree
Change index.
The content of the invention
The technical problems to be solved by the invention are to be difficult to inline diagnosis in the prior art, be difficult to the amount that provides interior leakage degree
There is provided inline diagnosis method is leaked in a kind of new gas valve for the problem of changing index.It is online that this method is used for leakage in gas valve
In diagnosis, have the advantages that inline diagnosis can be carried out, the quantizating index of interior leakage degree can be provided.
To solve the above problems, the technical solution adopted by the present invention is as follows:Leakage inline diagnosis method, root in a kind of gas valve
According to the functional relation characterized in gas valve between characteristics of Acoustic Emission parameter, characteristic parameter and the valves leakage slip leaked and
The upper lower limit value of leakage degree in various features parameter correspondence is different, establishes leakage diagnostic data base in gas valve, with interior leakage sound
Launch leakage in-circuit diagnostic system in data acquisition equipment composition gas valve, according to the grade distinguishing foundation of interior leakage degree, carry out
The inline diagnosis of leakage in gas valve;Establish the logarithm and acoustic emission signal average signal electricity that leak rate Q is sewed in gas valve
Relational expression between flat ASL is:
Wherein, R, T, P are respectively gas constant, temperature, pressure difference, and D is valve size, a0、a1、a2、a3For coefficient
Constant;In the gas valve leakage in-circuit diagnostic system include hardware setting, Diagnostic parameters, sampling setting, real time data,
Disconnected, historical data, valve account, diagnosis report, interior leakage diagnostic data base and interior leakage sound emission data acquisition equipment are inside failed to pinpoint a disease in diagnosis,
Wherein, interior leakage sound emission data acquisition equipment completes valves leakage signal acquisition, and interior leakage diagnostic data base provides different operating mode bars
Disconnected criteria data maintenance platform is failed to pinpoint a disease in diagnosis under part in gas valve, other items belong to man-machine interactive operation part;
In the gas valve leakage diagnostic data base include valve under different working conditions in fail to judge according to limit value, at least include
Functional relation between interior leak rate and characteristics of Acoustic Emission parameter ASL, amplitude, ASL, three characteristic parameter correspondences of energy are different
The upper lower limit value of interior leakage grade;
Obtained using interior leakage sound emission data acquisition equipment collection and characteristics of Acoustic Emission parameter value is leaked in current valve, based on gas trap
The relational expression between leak rate Q logarithm and acoustic emission signal average signal level ASL is sewed in door and is calculated under current working and is leaked
Rate Q, according to Q value first visits, obtains valves leakage grade;And then according to ASL, amplitude, three characteristic parameter correspondences of energy
The upper lower limit value of leakage grade further diagnoses leakage grade in current valve in different, and exports diagnosis report, otherwise obtains again
Characteristic ginseng value is taken, into next diagnosis circulation;Wherein, the interior leakage grade is divided into general leakage, medium leak, sternly
Three Estate is leaked again, according to leaking grade in valves leakage slip Q value span first visit current valves, and then according to ASL
Further whether diagnosis is in leakage rate range in corresponding for numerical value, amplitude value, energy values.
In above-mentioned technical proposal, it is preferable that the valve includes gate valve, stop valve.
In above-mentioned technical proposal, it is preferable that the pressure difference between valve inlet and outlet is in the range of 0.1MPa~3.0MPa.
The present invention is applied to leakage problem on line detection in gas valve for acoustic emission, proposes a kind of inline diagnosis method,
When solving leakage on-line checking in gas valve, testing result is easily affected by human factors problem.This method passes through theory analysis
With experimental verification means, the characteristics of Acoustic Emission parameter available for leakage in sign gas valve is found out, and obtain in gas valve
The mathematical relationship between FEATURE PARAMETERS OF ACOUSTIC EMISSION and interior leak rate is leaked, coefficient correlation is determined, and then set up leakage in gas valve
Diagnostic data base, according to the sound emission data acquisition equipment of the minimalist configuration requirement provided, with reference to interior leakage diagnostic data base,
Constitute leakage in-circuit diagnostic system in gas valve, it is proposed that diagnostic method, achieve preferable technique effect.
Embodiment
【Embodiment 1】
The present invention provides a kind of leakage inline diagnosis method in gas valve, and sign gas is have found by theory analysis and experimental verification
Functional relation between the characteristics of Acoustic Emission parameter and characteristic parameter and valves leakage rate of body valves leakage, various features parameter
The upper lower limit value of leakage degree in correspondence is different, establishes leakage diagnostic data base in gas valve, based on this, it is proposed that interior leakage journey
The grade distinguishing foundation and gas valves leakage inline diagnosis method of degree.
By carrying out different type valve interior stripping pattern draft experiment under the working conditions such as different pressure differences, interior leak rate, interior orifice sizes,
Leakage sound emission signal characteristic value in gas valve has been grasped, valves leakage slip logarithm and sound emission are drawn based on theory analysis
Mathematical relationship between signal averaging signal level (ASL), gives different diagnosis limit values based on experimental data, is stored in interior leakage
In diagnostic data base.
The different type valve includes gate valve, stop valve;
The different pressure difference operating modes refer to the pressure difference between valve inlet and outlet, and scope is in 0.1MPa~3.0MPa;
The characteristics of Acoustic Emission parameter at least includes amplitude, energy, ASL;
Valves leakage characteristics of Acoustic Emission parameter changes, valve types, two ends pressure difference, interior leakage with the change of valve applying working condition
It is larger that the factors such as hole size internally leak the influence of characteristics of Acoustic Emission parameter;
Under different pressure difference operating modes, the valve gas inner leakage sound emission amplitude, ASL, the linear variation characteristic of energy parameter;No
With under interior leak rate operating mode, the linear variation characteristic of the valve gas inner leakage sound emission amplitude and ASL parameters, energy parameter is in
Index variation characteristic;
The relation in leak rate Q logarithm and ASL between leakage acoustic emission signal ASL is sewed in the gas valve can use following formula table
Show:
Wherein, R, T, P, D are respectively gas constant, temperature, pressure difference, and D is valve size, and a0, a1, a2, a3 are
Coefficient constant, it follows that existing between valve gas inner leakage rate logarithm and acoustic emission signal average signal level (ASL)
Linear functional relation, and acoustic emission signal mainly influenceed by parameters such as valve size, valve pressure difference and released gas rates.
The valves leakage, when valves leakage hole size is more than certain threshold value (the present embodiment operating mode lower threshold value is in 0.8mm or so)
Afterwards, interior leakage Acoustic Emission Characteristic parameter value variation eases up.
Fig. 1 show leakage in-circuit diagnostic system structure chart in gas valve, including hardware setting, Diagnostic parameters, sampling set,
Real time data, interior fail to pinpoint a disease in diagnosis disconnected, historical data, valve account, diagnosis report, interior leakage diagnostic data base and interior leakage sound emission number
According to collecting device, wherein, interior leakage sound emission data acquisition equipment completes the collection of valves leakage acoustic emission signal, inside fails to pinpoint a disease in diagnosis disconnected number
There is provided according to storehouse and fail to pinpoint a disease in diagnosis disconnected criteria data maintenance platform in gas valve under different working conditions, other described items belong to man-machine friendship
Interoperate part.Wherein:
The interior leakage sound emission data acquisition equipment completes leakage sound emission data in gas valve and gathered completely, and completes data
Analysis, provides all parameters for characterizing acoustic emission signal, and the interior leakage sound emission data acquisition equipment is at least up to claimed below:
Response frequency:3kHz~1000kHz,
Analog filtering:Tri- high-pass filters of 20kHz, 100kHz, 400kHz, 100kHz, 400kHz, 1200kHz tri-
Low pass filter,
Noise minimum threshold:10dB,
Maximum signal amplitudes:100dB,
A/D translation types:Per passage 16bit,
Dynamic range:> 90dB,
Sampling rate:> 1M,
Sampling precision:During < 30dB, ± 5dB, during 30~40dB, ± 3dB, during 40~100dB, ± 2dB,
Clock accuracy:200ns,
Signal transmission rate:> 5MB/s.
At least providing the characteristic parameter of sign acoustic emission signal in real time includes:Amplitude, energy, ASL.
The interior leakage diagnostic data base at least includes the interior leakage Diagnostic parameters of different bore gate valves, stop valve, including the estimation of interior leak rate
Formula, general leakage, medium leak, the different interior leakage intensity grade upper lower limit values of serious leak, and provide different process bar
The upper lower limit value of the different interior leakage grades of ASL, amplitude, three characteristic parameter correspondences of energy under part.
The hardware setting completes sound emission data acquisition equipment data cube computation, sampling channel selection, filtering parameter setting etc.,
Finally complete hardware connection inspection, it is ensured that sound emission data acquisition equipment is correctly connected with inline diagnosis software systems.
The Diagnostic parameters selects corresponding process conditions, so as to proper use of interior leakage according to current detection valve process conditions
Various parameters in diagnostic data base, reasonable estimation Current Diagnostic valves leakage, it is determined that interior leakage grade.
The sampling is provided with acoustic emission signal collection various parameters and set, it is ensured that complete collection valves leakage sound emission letter
Number, Signal-to-Noise is improved as far as possible, for leaking acoustic emission signal collection, one group of preferred data acquisition ginseng in gas valve
Number is as follows:Threshold 37dB, sampling length 2048, blocking time 300us, parameter space 100us, locking time 1000us.
, can the real valves leakage acoustic emission signal of Detection and Extraction, and carry out correlated characteristic analysis completely based on this.
The real time data is according to set sampling parameter, collection Current Diagnostic valve acoustic emission signal, and completing in real time
Signal data analysis is there is provided original waveform figure, the related figure of various acoustic emission parameters, parameter list etc., and wherein parameter list is at least wrapped
Time, ASL, amplitude, three parameters of energy are reached containing signal.
Disconnected collection Current Diagnostic valve acoustic emission signal in real time is failed to pinpoint a disease in diagnosis in described, is failed to pinpoint a disease in diagnosis inside in real time according to the Diagnostic parameters disconnected
Suitable volume parameter value is selected in database, is usually no more than and provides within 20 seconds one group of diagnostic result, and is extracted beyond threshold value
Acoustic emission signal, calculates interior leak rate in real time, provides leakage grade diagnostic result in difference.
The historical data can provide valves leakage diagnosis with the data of off-line analysis other sound emission data acquisition equipments collection
As a result.
The valve account can safeguard that valve diagnosis are recorded, and include the letter such as valve essential information, service condition, diagnostic result
Breath, and search function is provided.
The diagnosis report includes the information such as diagnostic result and conclusion suggestion, and wherein diagnostic result comprises at least leakage signal width
Degree, ASL, three parameter maximums of energy, and interior leak rate-time correlation figure and leakage class result are provided, for working as
Preceding diagnostic result, provides conclusion suggestion.
Leakage in-circuit diagnostic system also includes data acquisition control in the gas valve, including at least data acquisition, suspends, stops
Only three buttons, so that operational control gathers effective valves leakage acoustic emission signal.
Fig. 2 show leakage inline diagnosis method flow diagram in gas valve, first, utilizes interior leakage sound emission data acquisition equipment
Collection obtains leakage characteristics of Acoustic Emission parameter value in current valve, and leak rate Q under current working is calculated based on formula (1), according to
Q value first visits, obtain valves leakage grade, and then according to leakage in ASL, amplitude, three characteristic parameter correspondence differences of energy etc.
The upper lower limit value of level further diagnoses leakage grade in current valve, and exports diagnosis report, otherwise reacquires characteristic parameter
Value, into next diagnosis circulation.
The inline diagnosis refers to that valve need not be dismantled, by installing the acquisition valves leakage sound emission of contact acoustic emission sensor
Characteristic ginseng value, normal production is not influenceed when failing to pinpoint a disease in diagnosis disconnected in carrying out;
The interior leakage grade is divided into general leakage, medium leak, serious leak Three Estate, according to valves leakage slip Q
It is worth leakage grade in span first visit current valve, and then is further diagnosed according to ASL numerical value, amplitude value, energy values
Whether in corresponding interior leakage rate range;
The interior leakage grade is according to interior leak rate Q calculated value tentative diagnosis, and when Q values are less than 10L/min not entering diagnosis follows
Ring, it is believed that leakage is not present in current working lower valve, when Q values are more than 10L/min and are less than or equal to numerical value 1, first visit
Current working lower valve is typically leaked, now, if ASL values are less than or equal to numerical value 3, amplitude is less than or equal to numerical value 5, energy
Amount is less than or equal to numerical value 7, is diagnosed as current working lower valve and typically leaks, and exports diagnosis report, otherwise reacquires feature
Parameter value, into next diagnosis circulation;
When Q values are more than numerical value 1 and are less than or equal to numerical value 2, first visit current working lower valve medium leak, now, such as
Fruit ASL values are more than numerical value 3 and are less than or equal to numerical value 4, and amplitude is more than numerical value 5 and is less than or equal to numerical value 6, and energy is more than numerical value 7
Less than or equal to numerical value 8, current working lower valve medium leak is diagnosed as, diagnosis report is exported, feature ginseng is otherwise reacquired
Numerical value, into next diagnosis circulation;
When Q values are more than numerical value 2, first visit current working lower valve serious leak, now, if ASL values are more than or equal to number
Value 4, amplitude is more than or equal to numerical value 6, and energy is more than or equal to numerical value 8, is diagnosed as current working lower valve serious leak, exports
Diagnosis report, otherwise reacquires characteristic ginseng value, into next diagnosis circulation;
The numerical value 1, numerical value 2, numerical value 3, numerical value 4, numerical value 5, numerical value 6, numerical value 7, numerical value 8 according to valve types,
The operating modes such as two ends pressure difference are different and different, and correlation values are obtained according to experiment and on-the-spot test experience, are stored in and interior fail to pinpoint a disease in diagnosis disconnected number
According in storehouse.
DN80 gate valves under 0.5MPa pressure difference working conditions in when failing to pinpoint a disease in diagnosis disconnected, numerical value 1, numerical value 2, numerical value 3, numerical value 4,
Numerical value 5, numerical value 6, numerical value 7, numerical value 8 be respectively 30L/min, 60L/min, 60dB, 70dB, 70dB, 80dB,
18000mv. μ s and 60000mv. μ s.
【Embodiment 2】
According to the condition and step described in embodiment 1, DN80 stop valves under 0.5MPa pressure difference working conditions in when failing to pinpoint a disease in diagnosis disconnected,
Numerical value 1, numerical value 2, numerical value 3, numerical value 4, numerical value 5, numerical value 6, numerical value 7, numerical value 8 be respectively 30L/min, 60L/min,
60dB, 66dB, 70dB, 78dB, 15000mv. μ s and 40000mv. μ s.