CN113145049A - Safety monitoring device for enamel of reaction kettle and damage positioning method - Google Patents

Safety monitoring device for enamel of reaction kettle and damage positioning method Download PDF

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Publication number
CN113145049A
CN113145049A CN202110378172.2A CN202110378172A CN113145049A CN 113145049 A CN113145049 A CN 113145049A CN 202110378172 A CN202110378172 A CN 202110378172A CN 113145049 A CN113145049 A CN 113145049A
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enamel
reaction kettle
voltage
electrode
sampling
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陈志模
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CHENGDU LIUHUI TECHNOLOGY CO.,LTD.
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Sichuan Liuhui Instrument Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/18Stationary reactors having moving elements inside
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0006Controlling or regulating processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053Details of the reactor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053Details of the reactor
    • B01J19/0066Stirrers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/02Apparatus characterised by being constructed of material selected for its chemically-resistant properties
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/02Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
    • G01N27/04Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance
    • G01N27/20Investigating the presence of flaws
    • G01N27/205Investigating the presence of flaws in insulating materials

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Electrochemistry (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
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  • Physical Or Chemical Processes And Apparatus (AREA)

Abstract

The invention discloses a safety monitoring device for enamel of a reaction kettle and a damage positioning method, comprising a probe electrode, a triode Q1, a relay JK1 and a sampling control unit; one end of a probe electrode is inserted into the reaction kettle to be contacted with a reaction medium, the other end of the probe electrode is connected with a power supply through a positive electrode protective resistor R1, and the probe electrode is also connected with a shell grounding point arranged on the outer wall of the steel container of the reaction kettle through a normally closed switch K1 and is grounded and connected to the base electrode of a triode Q1; the collector electrode of the triode Q1 is connected to a power supply, and the emitter electrode outputs voltage to the sampling control unit; the sampling control unit controls the normally closed switch K1 to be switched off at the beginning of detection through the relay JK1, and then compares the sampling voltage with a preset voltage threshold value to judge the damage degree of the inner layer of the enamel. The invention can monitor the running state of any enamel layer in the reaction kettle in full time, can display the damage state in real time, can eliminate high-voltage static generated by fluid media in the kettle, and avoids serious safety accidents caused by static sparks of the reaction kettle.

Description

Safety monitoring device for enamel of reaction kettle and damage positioning method
Technical Field
The invention relates to the technical field of detection of an enamel layer of a reaction kettle, in particular to a safety monitoring device for enamel of the reaction kettle and a damage positioning method.
Background
The reaction kettle is a main large-scale device of a chemical system. The enamel layer of the inner container of the reaction kettle is an acid and alkali resistant protective layer, and the occurrence of speck-shaped or crack-shaped damage to the enamel layer in different degrees is a common event under the action of factors such as thermal stress, mechanical stress, chemical corrosion and the like during operation. If the damage is not discovered in time and is correspondingly treated according to the degree, serious safety accidents such as rapid corrosion perforation of the metal body of the reaction kettle, leakage of reaction medium, shutdown and production halt can be caused.
At present, the method is generally adopted that before the feeding of a reaction kettle, a safety inspection worker visually inspects the reaction kettle, and when the reaction kettle is damaged, the reaction kettle enters the reaction kettle and is inspected whether enamel is seriously damaged (a metal body is exposed) by using a high-voltage spark leak detector. If no metal is exposed, the product can be used continuously; otherwise, the reaction kettle is replaced.
However, the prior inspection technology has the following defects: 1) the manual inspection is time-consuming, labor-consuming and low in efficiency, and the mass production is seriously influenced; 2) the blind area (namely the place which cannot be seen by the inspectors) exists in the manual inspection, and the missing inspection rate is high; 3) even more serious is the existence of a high time dead zone: the whole reaction kettle is in a condition of safety and incapability of inspection during the operation period of putting the reaction kettle into chemical reaction. If deep breakage of the enamel occurs during this period, a perforation leakage accident is inevitable.
Disclosure of Invention
In view of the above problems, the present invention aims to provide a safety monitoring device for enamel in a reaction kettle and a damage positioning method, which can not only fully automatically monitor the operation status of any enamel layer in the reaction kettle in all time periods and all airspaces, but also display corresponding status in real time, eliminate high-voltage static electricity generated by fluid media in the kettle, and avoid serious safety accidents caused by electrostatic sparks in the reaction kettle.
The technical scheme of the invention is as follows:
a safety monitoring device for enamel of a reaction kettle comprises a probe electrode, a triode Q1, a relay JK1, a sampling control unit and a shell grounding point, wherein the shell grounding point is arranged on the outer wall of a steel container of the reaction kettle and is connected with the ground;
one end of the probe electrode is inserted into the reaction kettle to be contacted with a reaction medium, the other end of the probe electrode is connected with a power supply through a positive electrode protection resistor R1, and the end of the probe electrode is also connected with a shell grounding point and a base electrode of a triode Q1 through a normally closed switch K1; the collector electrode of the triode Q1 is connected to a power supply, and the emitter electrode outputs voltage to the sampling control unit;
the sampling control unit controls the normally closed switch K1 to be switched off to sample the output voltage at the sampling moment through the relay JK1, and then the sampled voltage is compared with a preset voltage threshold value to judge the damage degree of the inner layer of the enamel.
Further, the device also comprises a display unit and an alarm unit; if the sampling voltage is less than the first voltage threshold, the display unit indicates 'normal'; if the sampling voltage is greater than the first voltage threshold and less than the second voltage threshold, the display unit indicates light damage; if the sampling voltage is larger than the second voltage threshold value, the display unit indicates 'damage', and the alarm unit sends out an audible and visual alarm signal.
Further, the voltage threshold is set according to the kind of the reaction medium.
Furthermore, the probe electrode is arranged at the bottom of the reaction kettle and is sealed by a polytetrafluoroethylene gasket.
Furthermore, the probe electrode A is a tantalum wire probe electrode.
Furthermore, the sampling control unit processes the sampling data through the CPU chip and sends the processed data to the remote monitoring center.
A damage positioning method based on a reactor enamel safety monitoring device comprises the following steps:
step 1: when the alarm unit sends out an audible and visual alarm signal, the stirring is immediately stopped;
step 2: opening the discharge valve to discharge the reaction medium slowly at a certain flow rate;
and step 3: when the acousto-optic alarm signal stops, immediately closing the discharge valve, observing and recording the liquid level of the reaction medium, wherein the damaged part is in a section of annular inner wall range above the liquid level;
and 4, step 4: discharging all reaction medium, determining the specific position of the damage in the range of the annular inner wall, and timely repairing.
Compared with the prior art, the invention has the following beneficial effects:
1. the monitoring is full-automatic, and manual participation is not needed; monitoring has no space dead angle, and all the spaces which can be touched by reaction media in the reaction kettle are the effective monitoring range of the system;
2. the monitoring is carried out in all time periods, and as long as a reaction medium exists in the reaction kettle, the system is in a monitoring state even in the working state of the reaction kettle;
3. the invention has fast response time, and the enamel damage can be found out in seconds at the fastest speed;
4. the measuring probe electrode of the monitoring system is contacted with a reaction liquid medium of the reaction kettle, and electrostatic charges generated by the reaction medium due to stirring are led to the grounding discharge loop through the monitor, so that the static electricity is thoroughly eliminated, and the potential safety hazard which is most commonly existed in the chemical industry is completely eradicated; meanwhile, the interference of static electricity on the sampling voltage can be effectively eliminated, and the detection result is more accurate.
Drawings
FIG. 1 is a schematic structural diagram of a reactor enamel safety monitoring device of the present invention.
In the figure: 1-a motor; 2-a stirrer; 3-a reaction kettle; 4-housing ground; 5-a polytetrafluoroethylene gasket; 6-a release valve; 7-enamel inner layer; 8-a steel container; 9-a reaction medium; 10-probe electrode.
Detailed Description
The invention is described in further detail below with reference to the figures and specific embodiments.
Example 1: the reactor enamel safety monitoring device shown in fig. 1 comprises a probe electrode 10, a triode Q1, a relay JK1, a sampling control unit and a shell grounding point 4 which is arranged on the outer wall of a steel container 8 of a reactor 3 and is connected with the ground; one end of the probe electrode 10 is inserted into the reaction kettle 3 to be contacted with the reaction medium 9, the other end of the probe electrode is connected with a power supply through a positive electrode protection resistor R1, and the end of the probe electrode is also connected with the shell grounding point 4 and the base electrode of the triode Q1 through a normally closed switch K1; the collector electrode of the triode Q1 is connected to a power supply, and the emitter electrode outputs voltage to the sampling control unit; the sampling control unit controls the normally closed switch K1 to be switched off to sample the output voltage at the sampling moment through the relay JK1, and then compares the sampled voltage with a preset voltage threshold value to judge the damage degree of the enamel inner layer 7.
The normally closed switch K1 controlled by the relay JK1 makes the probe A and the metal shell B point of the reaction kettle short-circuit, and connects the high-voltage static electricity generated by the reaction medium and the induced charge generated by the metal container to the ground through the lead and releases the high-voltage static electricity. And (3) the K1 is cut off at the moment of detection, Vi is output, and a corresponding monitoring indication signal is given after the current amplification, A/D conversion, storage, discrimination, control and the like of a post-stage circuit.
According to the invention, the reaction medium 8 and the shell grounding point 4 are connected through the normally closed switch K1 of the relay and then connected to the ground, so that static electricity rapidly accumulated due to high-speed stirring is eliminated in time, on one hand, potential safety hazards caused by the static electricity can be avoided, on the other hand, interference of the static electricity on a sampling signal can be eliminated during voltage sampling, and the detection result is more accurate. The relay is selected for use in the discharging loop, so that the functions can be conveniently and effectively realized. In the non-sampling time period, the normally closed switch K1 is in a closed state, static electricity generated in the reaction kettle can be smoothly and timely discharged into the ground, and no static electricity accumulation is generated, which is not reached by elements such as a lightning protection diode. Because no static electricity is accumulated, at the sampling point, namely the moment of disconnecting the normally closed switch K1 and the reaction medium 8 and the shell grounding point 4, the collected voltage signal can more truly reflect the damage condition of the enamel layer, and the misjudgment caused by static electricity interference is avoided.
Example 2: the device also comprises a display unit and an alarm unit; if the sampling voltage is smaller than the first voltage threshold value, the display unit indicates 'normal' and lights a green light; if the sampling voltage is greater than the first voltage threshold and less than the second voltage threshold, the display unit indicates light injury and a yellow lamp is lighted; if the sampling voltage is larger than the second voltage threshold value, the display unit indicates 'damage', and the alarm unit sends out an audible and visual alarm signal to light a red light.
The voltage threshold can be set according to the type of the reaction medium 9, and can be set according to the conductivity of the reaction medium 9.
The insulation resistance of the enamel layer is detected by using a voltage division loop, and the circuit has the advantages of simple and reliable structure and strong anti-interference capability. In fig. 1, a +5V power supply, a positive electrode protection resistor R1, a probe electrode A, Rx, a grounding resistor R0, a normally closed switch K1 and a negative electrode are connected in series to form a voltage division loop, Rx is the total resistance between a reaction medium of an enamel kettle and a steel container of the reaction kettle, and Rx is mainly determined by the condition of an enamel inner layer of the reaction kettle. The detection conditions are divided into the following cases:
1) if the enamel layer is intact, the insulation resistance of Rx is very large, and the potential Vi transferred to the base electrode of the triode Q1 through the voltage division loop is very low;
2) if the enamel layer is damaged and the Rx resistance of the insulating layer becomes thinner and smaller, Vi is increased;
3) when the damage of the enamel layer is serious, so that the metal container is in direct contact with the reaction medium, Rx can be reduced to the minimum, the voltage Vi converted into the base electrode of Q1 through the voltage division loop reaches a large value, and the alarm circuit gives out an acoustic and optical alarm signal after being triggered.
Although the ground glaze of the enamel liner has stronger adhesiveness, the insulation and corrosion resistance are lower than those of the external enamel layer, so if cracks exist in the enamel layer, Rx becomes smaller as the depth of the cracks increases. Moreover, in actual production, the enamel layer goes through a process from the time of cracking to the time of complete breaking to expose the ground coat for several days or tens of days, and if the outer steel container is exposed, the dissolution and penetration occur within one to two hours to cause the leakage of the reaction medium. Therefore, a larger numerical span exists between the first voltage threshold and the second voltage threshold, once the yellow lamp is turned on in the test, the light damage such as shallow cracks begins to appear on the enamel layer, the enamel layer can be continuously used, early warning is sent out in advance, and the follow-up production adjustment and repair preparation can be conveniently arranged in advance.
Example 3: the probe electrode 10 is arranged at the bottom of the reaction kettle 3 and sealed by a polytetrafluoroethylene gasket 5, and the probe electrode 10 is a tantalum wire probe electrode. The invention relates to a probe electrode of an embedded insulating sealing gasket, wherein a tantalum metal wire is embedded into a polytetrafluoroethylene sealing gasket to be used as a measuring probe and is arranged at a discharge hole of a reaction kettle. The inner side of the tantalum wire is exposed and contacted with a reaction medium, and the outer side of the tantalum wire is connected with +5V bias voltage of a monitor through a lead; the structure plays a role in insulating and sealing (preventing a reaction medium from leaking outwards), and the probe electrode can be arranged at the lowest end of the reaction kettle, so that the full-space monitoring effect is achieved, and the probe electrode is not limited by the height of the liquid level of the medium.
The probe electrode of the invention is connected with the shell and the ground through the relay normally closed switch, so that the static electricity generated by the liquid medium flowing at high speed in the reaction kettle can be reliably eliminated, and the greatest hidden danger caused by static discharge in a chemical workshop is eliminated. The invention processes the measured data by CPU chip, can carry out remote centralized monitoring through data bus, and can set different monitoring alarm threshold resistances according to different reaction media.
Example 4: when the damage is detected, the invention also provides a simple and effective damage positioning method, which comprises the following specific steps:
step 1: when the alarm unit sends out sound and light alarm signals, the stirring is stopped immediately.
Step 2: opening the discharge valve to discharge the reaction medium slowly at a certain flow rate; the liquid level dropping speed of this example was 2 cm/min.
And step 3: when the audible and visual alarm signal stops, the material drainage valve is immediately closed, the liquid level of the reaction medium is observed and recorded, and the damaged part is positioned in a section (1-4 cm) above the liquid level and is positioned in the range of the annular inner wall.
And 4, step 4: discharging all reaction medium, determining the specific position of the damage in the range of the annular inner wall, and timely repairing.
The positioning method is simple and effective, can quickly position the damaged position, can avoid secondary damage of the existing electrode detection method to the enamel layer, and is more rigorous, accurate and efficient compared with the existing method of only manually checking by naked eyes.

Claims (7)

1. The monitoring device for the enamel safety of the reaction kettle is characterized by comprising a probe electrode (10), a triode Q1, a relay JK1, a sampling control unit and a shell grounding point (4) which is arranged on the outer wall of a steel container (8) of the reaction kettle (3) and is connected with the ground;
one end of the probe electrode (10) is inserted into the reaction kettle (3) to be contacted with the reaction medium (9), the other end of the probe electrode is connected with a power supply through a positive electrode protective resistor R1, and the end of the probe electrode is also connected with a shell grounding point (4) and a base electrode of a triode Q1 through a normally closed switch K1; the collector electrode of the triode Q1 is connected to a power supply, and the emitter electrode outputs voltage to the sampling control unit;
the sampling control unit controls the normally closed switch K1 to be switched off to sample the output voltage at the sampling moment through the relay JK1, and then the sampled voltage is compared with a preset voltage threshold value to judge the damage degree of the enamel inner layer (7).
2. The reactor enamel safety monitoring device as claimed in claim 1, further comprising a display unit and an alarm unit; if the sampling voltage is less than the first voltage threshold, the display unit indicates 'normal'; if the sampling voltage is greater than the first voltage threshold and less than the second voltage threshold, the display unit indicates light damage; if the sampling voltage is larger than the second voltage threshold value, the display unit indicates 'damage', and the alarm unit sends out an audible and visual alarm signal.
3. Reactor enamel safety monitoring device according to claim 1 or 2, characterized in that the voltage threshold is set according to the kind of reaction medium (9).
4. The reactor enamel safety monitoring device according to claim 1, wherein the probe electrode (10) is installed at the bottom of the reactor (3) and sealed by a polytetrafluoroethylene gasket (5).
5. The reactor enamel safety monitoring device as claimed in claim 1, wherein the probe electrode (10) is a tantalum wire probe electrode.
6. The reactor enamel safety monitoring device as claimed in claim 1, wherein the sampling control unit processes the sampling data through a CPU chip and sends the processed data to a remote monitoring center.
7. A method for positioning breakage of a reactor enamel safety monitoring device based on claim 2, which is characterized by comprising the following steps:
step 1: when the alarm unit sends out an audible and visual alarm signal, the stirring is immediately stopped;
step 2: opening the discharge valve to discharge the reaction medium slowly at a certain flow rate;
and step 3: when the acousto-optic alarm signal stops, immediately closing the discharge valve, observing and recording the liquid level of the reaction medium, wherein the damaged part is in a section of annular inner wall range above the liquid level;
and 4, step 4: discharging all reaction medium, determining the specific position of the damage in the range of the annular inner wall, and timely repairing.
CN202110378172.2A 2021-04-08 2021-04-08 Safety monitoring device for enamel of reaction kettle and damage positioning method Pending CN113145049A (en)

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CN202110378172.2A CN113145049A (en) 2021-04-08 2021-04-08 Safety monitoring device for enamel of reaction kettle and damage positioning method

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1369104A (en) * 1971-10-29 1974-10-02 Pfaudler Werke Ag Method and apparatus for the detection of damage to an enamel layer
CN103913282A (en) * 2014-04-11 2014-07-09 中冶南方工程技术有限公司 Leakage detection method for closed circulating water system of calcium carbide furnace
CN205020081U (en) * 2015-09-25 2016-02-10 泰兴市臻庆化工有限公司 Prevent static reation kettle
CN205656230U (en) * 2016-04-21 2016-10-19 山东大地盐化集团有限公司 Damaged online alarm device of enamel reactor
CN209188755U (en) * 2018-10-24 2019-08-02 广州市粤新工程技术有限公司 A kind of H-1072 passivation film agent manufacture reaction kettle
CN214599055U (en) * 2021-04-08 2021-11-05 四川六惠仪器仪表有限公司 Safety monitoring device for enamel of reaction kettle

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1369104A (en) * 1971-10-29 1974-10-02 Pfaudler Werke Ag Method and apparatus for the detection of damage to an enamel layer
CN103913282A (en) * 2014-04-11 2014-07-09 中冶南方工程技术有限公司 Leakage detection method for closed circulating water system of calcium carbide furnace
CN205020081U (en) * 2015-09-25 2016-02-10 泰兴市臻庆化工有限公司 Prevent static reation kettle
CN205656230U (en) * 2016-04-21 2016-10-19 山东大地盐化集团有限公司 Damaged online alarm device of enamel reactor
CN209188755U (en) * 2018-10-24 2019-08-02 广州市粤新工程技术有限公司 A kind of H-1072 passivation film agent manufacture reaction kettle
CN214599055U (en) * 2021-04-08 2021-11-05 四川六惠仪器仪表有限公司 Safety monitoring device for enamel of reaction kettle

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