CN113916453B - Method for quickly finding leakage and locking leakage valve - Google Patents
Method for quickly finding leakage and locking leakage valve Download PDFInfo
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- CN113916453B CN113916453B CN202111201014.6A CN202111201014A CN113916453B CN 113916453 B CN113916453 B CN 113916453B CN 202111201014 A CN202111201014 A CN 202111201014A CN 113916453 B CN113916453 B CN 113916453B
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- 238000000034 method Methods 0.000 title claims abstract description 22
- 238000004458 analytical method Methods 0.000 claims abstract description 40
- 238000004868 gas analysis Methods 0.000 claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims abstract description 16
- 230000003203 everyday effect Effects 0.000 claims abstract description 5
- 238000005070 sampling Methods 0.000 claims abstract description 5
- 238000004200 deflagration Methods 0.000 claims description 4
- 238000001514 detection method Methods 0.000 abstract description 9
- 239000000463 material Substances 0.000 abstract description 3
- 239000007789 gas Substances 0.000 description 76
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000003086 colorant Substances 0.000 description 2
- 238000002372 labelling Methods 0.000 description 2
- 238000012216 screening Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000003245 coal Substances 0.000 description 1
- 230000002354 daily effect Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M3/00—Investigating fluid-tightness of structures
- G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
- G01M3/04—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M3/00—Investigating fluid-tightness of structures
- G01M3/002—Investigating fluid-tightness of structures by using thermal means
Abstract
The invention discloses a method for quickly finding leakage and locking a leakage valve, which comprises the following steps: firstly, establishing a gas torch blow-down gas analysis comparison database for analyzing gas of a torch gas and a torch main pipe, then adding an online analyzer on the torch main pipe or sampling and analyzing the gas torch main pipe every day, establishing a gas torch main pipe analysis statistical database, comparing analysis components in the two databases, and marking when the content of a certain component changes by more than +/-10 percent and judging that the gas leakage of a production system occurs when no person blow down; after the leakage is determined by comparison, the gas components of the torch header pipes in the two databases are compared by using a formula, and a gas source capable of correspondingly changing the gas of the gas torch header pipes is found out, so that a leakage-occurring emptying valve is locked. The invention solves the problems of large workload and high labor cost of the existing valve detection method. The invention can reduce manpower and material resources and can discover valve leakage in time.
Description
Technical Field
The invention belongs to the field of valve leakage detection, and particularly relates to a method for quickly finding leakage and locking a leakage valve.
Background
Modern large-scale coal chemical enterprises have complex processes, long flow, and large numbers of safety valves and vent valves, and once the valves leak, a large amount of effective gas can be put into a torch for burning, so that waste is caused, and the production cost is increased.
The traditional leak detection method is that an operator detects the temperature behind the vent valve by using a temperature measuring gun, judges the valve leakage when the temperature is higher than the ambient temperature, the method can not detect whether the vent valve of normal-temperature gas leaks inwards, and because the number of the vent valves or the safety valves is numerous, manufacturers can not detect the valve in a daily way, when the valve leaks, a large amount of effective gas can not be timely found, thus the production cost and the energy waste are increased, and the traditional detection method needs to measure the temperature by one valve, has large workload and long detection time, and increases the labor cost.
Disclosure of Invention
In order to overcome the defects of large workload and high labor cost of the existing valve detection method, the invention provides a method for quickly finding leakage and locking a leakage valve, which can reduce manpower and material resources and can find the leakage of the valve in time.
The technical scheme adopted by the invention for achieving the purpose is as follows:
a method of quickly discovering leaks and locking a leaking valve, comprising the steps of: firstly, a gas torch emptying gas analysis comparison database for analyzing the gas of the torch main pipe is established, then an online analyzer is added on the torch main pipe or sampling analysis is carried out on the torch main pipe every day, a gas torch main pipe analysis statistical database is established, gas analysis components in the gas torch main pipe analysis statistical database are compared with the gas analysis components of the torch main pipe in the gas torch emptying gas analysis comparison database, when the content of a certain component changes by more than +/-10%, the gas is marked at the same time, and when the production system does not have artificial emptying, the occurrence of gas leakage of the production system can be judged, so that the gas components of the torch main pipe change; after the leakage is determined through comparison, comparing the flare header gas analysis components in the gas flare header analysis statistics database with the flare header gas components in the gas flare blow-out gas analysis comparison database by using a formula, counting which components are changed, and comparing the components blown out by using the change characteristics in all devices of the comparison database to find out a gas source capable of correspondingly changing the gas of the gas flare header, namely locking a blow-out valve with the leakage; if a plurality of gas blow-down conforming to the characteristics exist, a method of measuring by a temperature measuring gun and opening and closing a front hand valve of the blow-down valve is adopted to discriminate, and a leakage valve is found.
Further, the step of establishing a comparison database of the analysis of the gas of the deflagration torch and the gas of the torch header pipe is as follows: and when the production is normal, namely the valve is normally checked and is not leaked, the quality monitoring center performs detailed analysis and recording on the flare header pipe and the components of the discharged gas of each device, and Excel software is utilized to perform arrangement statistics according to the discharged valve and analysis items to be used as a gas flare discharged gas analysis comparison database.
Further, the statistical database is formed by using Excel software to arrange and count data sampled and analyzed from the flare header according to time and analysis project rows, and is used as a gas flare header analysis statistical database.
Further, the step of simultaneously labeling when a change of more than + -10% occurs in the content of a certain component is: the components with the change of more than +/-10% are automatically marked according to a judging formula.
Further, the judgment formula is as follows: (1) In the gas torch header analysis statistical database, a screening formula is formed in a newly input torch header analysis remark column of each row: IF (AND (0.9)<B X /B 3 <1.1，0.9<C X /C 3 <1.1，0.9<D X /D 3 <1.1，0.9<E X /E 2 <1.1，0.9<F X /F 2 <1.1，0.9<G X /G 2 <1.1，0.9<H X /H 2 <1.1，0.9<I X /I 2 <1.1，0.9<J X /J 2 <1.1 "no internal leakage", "X in the formula represents the X line, when 10% deviation occurs in each index analysis of internal leakage flare gas occurs in the system blow-out valve or the safety valve, the remark column in the database will display" internal leakage "; (2) After the mark of 'internal leakage' appears, the internal leakage condition of the vent valve or the safety valve is indicated, the 'condition format' and the 'highlighting cell rule' are utilized by opening the 'gas torch vent gas analysis comparison database', the data of each component of the torch gas when the internal leakage appears are respectively compared with the data of each component in the 'gas torch vent gas analysis comparison database', the data which can respectively cause the change of the torch components are marked with different colors, and a plurality of marks are simultaneously satisfiedThe noted lock is the leak location.
Further, the method for measuring and opening and closing the front hand valve of the vent valve by using the temperature measuring gun is further screened, and the step of finding out the leakage valve is as follows: (1) if the temperature difference between the temperature of the air and the ambient temperature exceeds 10 ℃, the temperature of the pipeline behind the air valve can be measured by a temperature measuring gun, and if the deviation between the temperature of the pipeline behind the air valve and the room temperature is more than 5 ℃, the air valve is considered to leak; (2) if the temperature difference between the atmospheric gas temperature and the ambient temperature is lower than 10 ℃, the suspected atmospheric valve front hand valves are closed one by one, the flare header pipe is sampled and analyzed after the suspected atmospheric valve front hand valves are closed for 30 minutes, the atmospheric gas components of the flare header pipe are recovered after the analytical data are judged to be closed, and the leakage of the atmospheric valve is indicated, and the leakage valve is locked.
The invention can timely and quickly find out leakage of the vent valve or the safety valve, thereby avoiding great economic loss for production enterprises; the problem that whether the normal-temperature gas leakage-proof valve leaks or not cannot be detected by the traditional leak detection method can be solved; the manpower and material resources required by leak detection are greatly reduced, and the detection cost is reduced.
Successful application cases: by adopting the method, we (Hua company) successfully find and quickly lock the leakage of the PV1004 of the vent valve 22 at the outlet of the low-temperature methanol washing device, and the leakage of the effective gas near normal temperature (30 ℃) in the valve is timely treated, so that the economic loss of 10.85 ten thousand yuan/day is recovered for the company.
Detailed Description
The method for quickly finding leakage and locking the leakage valve in the embodiment comprises the following steps: firstly, a gas torch emptying gas analysis comparison database for analyzing the gas of the torch main pipe is established, then an online analyzer is added on the torch main pipe or sampling analysis is carried out on the torch main pipe every day, a gas torch main pipe analysis statistical database is established, gas analysis components in the gas torch main pipe analysis statistical database are compared with the gas analysis components of the torch main pipe in the gas torch emptying gas analysis comparison database, when the content of a certain component changes by more than +/-10%, the gas is marked at the same time, and when the production system does not have artificial emptying, the occurrence of gas leakage of the production system can be judged, so that the gas components of the torch main pipe change; after the leakage is determined through comparison, comparing the flare header gas analysis components in the gas flare header analysis statistics database with the flare header gas components in the gas flare blow-out gas analysis comparison database by using a formula, counting which components are changed, and comparing the components blown out by using the change characteristics in all devices of the comparison database to find out a gas source capable of correspondingly changing the gas of the gas flare header, namely locking a blow-out valve with the leakage; if a plurality of gas blow-down conforming to the characteristics exist, a method of measuring by a temperature measuring gun and opening and closing a front hand valve of the blow-down valve is adopted to discriminate, and a leakage valve is found.
Further, the step of establishing a comparison database of the analysis of the gas of the deflagration torch and the gas of the torch header pipe is as follows: and when the production is normal, namely the valve is normally checked and is not leaked, the quality monitoring center performs detailed analysis and recording on the flare header pipe and the components of the discharged gas of each device, and Excel software is utilized to perform arrangement statistics according to the discharged valve and analysis items to be used as a gas flare discharged gas analysis comparison database.
Further, the statistical database is formed by using Excel software to arrange and count data sampled and analyzed from the flare header according to time and analysis project rows, and is used as a gas flare header analysis statistical database.
Further, the step of simultaneously labeling when a change of more than + -10% occurs in the content of a certain component is: the components with the change of more than +/-10% are automatically marked according to a judging formula.
Further, the judgment formula is as follows: (1) In the gas torch header analysis statistical database, a screening formula is formed in a newly input torch header analysis remark column of each row: IF (AND (0.9)<B X /B 3 <1.1，0.9<C X /C 3 <1.1，0.9<D X /D 3 <1.1，0.9<E X /E 2 <1.1，0.9<F X /F 2 <1.1，0.9<G X /G 2 <1.1，0.9<H X /H 2 <1.1，0.9<I X /I 2 <1.1，0.9<J X /J 2 <1.1 "no internal leakage", "X in the formula represents the X line, when 10% deviation occurs in each index analysis of internal leakage flare gas occurs in the system blow-out valve or the safety valve, the remark column in the database will display" internal leakage "; (2) After the mark of 'internal leakage' appears, the internal leakage condition of the vent valve or the safety valve is indicated, the 'condition format' and the 'highlighting cell rule' are utilized by opening the 'gas torch vent gas analysis comparison database', the data of each component of the torch gas when the internal leakage exists are respectively compared with the data of each component in the 'gas torch vent gas analysis comparison database', the data which can respectively cause the change of the torch components are marked with different colors, and the locking of a plurality of marks is satisfied as the leakage position.
Further, the method for measuring and opening and closing the front hand valve of the vent valve by using the temperature measuring gun is further screened, and the step of finding out the leakage valve is as follows: (1) if the temperature difference between the temperature of the air and the ambient temperature exceeds 10 ℃, the temperature of the pipeline behind the air valve can be measured by a temperature measuring gun, and if the deviation between the temperature of the pipeline behind the air valve and the room temperature is more than 5 ℃, the air valve is considered to leak; (2) if the temperature difference between the atmospheric gas temperature and the ambient temperature is lower than 10 ℃, the suspected atmospheric valve front hand valves are closed one by one, the flare header pipe is sampled and analyzed after the suspected atmospheric valve front hand valves are closed for 30 minutes, the atmospheric gas components of the flare header pipe are recovered after the analytical data are judged to be closed, and the leakage of the atmospheric valve is indicated, and the leakage valve is locked.
Specific examples:
1. a comparison database of the analysis of the deflagration torch gas and the torch manifold gas is established. The quality monitoring center performs detailed analysis and recording on the flare header pipe and the components of the discharged gas of each device during normal production (when the valve check is normal and is not leaked), and Excel software is utilized to calculate the gas components according to the discharged valve and analysis items (CO, CO) 2 、N 2 、H 2 、Ar、CH 4 、H 2 S、COS、CH 3 OH) as a comparison database.
The component characteristics of the gases of different devices can be greatly changed after the gases are reacted,for example, the CO content in the gasified raw gas discharged air is 63 percent, H 2 Content 25%, CH 4 At a content of 100ppm, H 2 After the S content is 6000ppm and the reaction is carried out by a conversion device, the content of CO discharged from a conversion outlet is 22 percent and the content of H is high 2 Content of 44%, CH 4 Content of 1000ppm, H 2 After the S content is 6000ppm and passes through the low-grade armor device, the CO content of the low-grade armor outlet is 30 percent and the H content is high 2 67% of CH 4 Content of 1000ppm, H 2 S content 0.1ppm, these gas components normally fluctuate over a range of less than 10%, we use these differences to quickly identify and lock the vent valve of the leak device.
2. Adding an online analyzer on a torch manifold or sampling and analyzing the torch manifold every day, and utilizing Excel software to analyze the analysis data according to time and analysis projects (CO, CO) 2 、N 2 、H 2 、Ar、CH 4 、H 2 S、COS、CH 3 OH) is used as a statistical database and is compared with the analysis components of the background torch header gas in a comparison database, and when a certain component (CO, CO) 2 、N 2 、H 2 、Ar、CH 4 、H 2 S、COS、CH 3 When the OH) content is changed by more than +/-10%, the components with the change of more than +/-10% are automatically marked as red according to a judging formula of Excel, and when the production system is not manually emptied, the occurrence of gas leakage of the production system can be judged, so that the gas components of the torch manifold are changed.
3. After the leakage is determined through comparison, comparing the flare header gas analysis components with flare header gas components in a ratio database by using a formula, and counting which components are changed, for example: h 2 Rise in content of CO 2 Reduced content of H 2 S content decreases, etc., by whichThe change characteristics are compared in the comparison database to compare the components of the air discharged by all devices, and an air source which can correspondingly change the gas of the gas torch main pipe is found, so that a leakage-appearing vent valve is locked, and the workload of checking the leakage valve is greatly reduced.
4. If a plurality of gas blow-down conforming to the characteristics exist, a method of measuring by a temperature measuring gun and opening and closing a front hand valve of the blow-down valve is adopted to discriminate, and a leakage valve is found: (1) if the temperature difference between the temperature of the air and the ambient temperature exceeds 10 ℃, the temperature of the pipeline behind the air valve can be measured by a temperature measuring gun, and if the deviation between the temperature of the pipeline behind the air valve and the room temperature is more than 5 ℃, the air valve is considered to leak; (2) if the temperature difference between the atmospheric gas temperature and the ambient temperature is lower than 10 ℃, the suspected atmospheric valve front hand valves are closed one by one, the flare header pipe is sampled and analyzed after the suspected atmospheric valve front hand valves are closed for 30 minutes, the atmospheric gas components of the flare header pipe are recovered after the analytical data are judged to be closed, and the leakage of the atmospheric valve is indicated, and the leakage valve is locked.
Claims (5)
1. A method of quickly discovering a leak and locking a leaking valve, comprising the steps of: firstly, a gas torch emptying gas analysis comparison database for analyzing the gas of the torch main pipe is established, then an online analyzer is added on the torch main pipe or sampling analysis is carried out on the torch main pipe every day, a gas torch main pipe analysis statistical database is established, gas analysis components in the gas torch main pipe analysis statistical database are compared with the gas analysis components of the torch main pipe in the gas torch emptying gas analysis comparison database, when the content of a certain component changes by more than +/-10%, the gas is marked at the same time, and when the production system does not have artificial emptying, the occurrence of gas leakage of the production system can be judged, so that the gas components of the torch main pipe change; after the leakage is determined through comparison, comparing the gas analysis components of the gas main pipe in the gas main pipe analysis and statistics database with the gas components of the gas main pipe in the gas main pipe blow-out gas analysis and comparison database by using a formula, counting which components are changed, comparing the components of the blow-out gas in all devices of the comparison database by using the change characteristics, and finding out a gas source capable of correspondingly changing the gas of the gas main pipe, namely locking a blow-out valve with the leakage; if a plurality of gas blow-down conforming to the characteristics exist, a method of measuring by a temperature measuring gun and opening and closing a front hand valve of the blow-down valve is adopted to discriminate, and a leakage valve is found.
2. The method of quickly discovering leaks and locking leak valves of claim 1, wherein the step of creating a gas flare vent gas analysis comparison database of the deflagration torch gas and the flare header gas is: and when the production is normal, namely the valve is normally checked and is not leaked, the quality monitoring center performs detailed analysis and recording on the flare header pipe and the components of the discharged gas of each device, and Excel software is utilized to perform arrangement statistics according to the discharged valve and analysis items to be used as a gas flare discharged gas analysis comparison database.
3. The method for quickly finding leakage and locking a leakage valve according to claim 1, wherein the statistical database is a gas flare manifold analysis statistical database which uses Excel software to arrange statistics according to time and analysis item lines of data sampled and analyzed from a flare manifold.
4. The method of quickly discovering leaks and locking leaking valves of claim 1, wherein the step of simultaneously marking when a component content varies by greater than ± 10% is: the components with the change of more than +/-10% are automatically marked according to a judging formula.
5. The method for quickly detecting leakage and locking a leakage valve according to claim 1, wherein the method for measuring and opening and closing a front hand valve of a vent valve by using a temperature measuring gun is further distinguished, and the step of finding the leakage valve is as follows: (1) if the temperature difference between the temperature of the air and the ambient temperature exceeds 10 ℃, the temperature of the pipeline behind the air valve can be measured by a temperature measuring gun, and if the deviation between the temperature of the pipeline behind the air valve and the room temperature is more than 5 ℃, the air valve is considered to leak; (2) if the temperature difference between the atmospheric gas temperature and the ambient temperature is lower than 10 ℃, the suspected atmospheric valve front hand valves are closed one by one, the flare header pipe is sampled and analyzed after the suspected atmospheric valve front hand valves are closed for 30 minutes, the atmospheric gas components of the flare header pipe are recovered after the analytical data are judged to be closed, and the leakage of the atmospheric valve is indicated, and the leakage valve is locked.
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Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3448533C2 (en) * | 1983-07-29 | 1996-10-17 | Panametrics | Acoustic leak detection system for flare stack pipework |
| KR20140041623A (en) * | 2014-01-02 | 2014-04-04 | 삼성중공업 주식회사 | Flare line and monitoring system thereof |
| CN104122037A (en) * | 2013-04-28 | 2014-10-29 | 宝山钢铁股份有限公司 | Method for detecting internal leakage of gas valve of industrial furnace online by utilizing furnace temperature change |
| CN205426424U (en) * | 2016-03-23 | 2016-08-03 | 中国石油化工股份有限公司 | Leak online diagnosis platform in gas valve |
| CN107228740A (en) * | 2016-03-23 | 2017-10-03 | 中国石油化工股份有限公司 | Leakage inline diagnosis method in gas valve |
| CN209992134U (en) * | 2019-05-10 | 2020-01-24 | 华帝股份有限公司 | Device for detecting air tightness of torch valve body |
| CN111929114A (en) * | 2020-09-08 | 2020-11-13 | 南京分析仪器厂有限公司 | Petrochemical industry torch discharges on-line monitoring system of waste gas component and calorific value |
-
2021
- 2021-10-15 CN CN202111201014.6A patent/CN113916453B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3448533C2 (en) * | 1983-07-29 | 1996-10-17 | Panametrics | Acoustic leak detection system for flare stack pipework |
| CN104122037A (en) * | 2013-04-28 | 2014-10-29 | 宝山钢铁股份有限公司 | Method for detecting internal leakage of gas valve of industrial furnace online by utilizing furnace temperature change |
| KR20140041623A (en) * | 2014-01-02 | 2014-04-04 | 삼성중공업 주식회사 | Flare line and monitoring system thereof |
| CN205426424U (en) * | 2016-03-23 | 2016-08-03 | 中国石油化工股份有限公司 | Leak online diagnosis platform in gas valve |
| CN107228740A (en) * | 2016-03-23 | 2017-10-03 | 中国石油化工股份有限公司 | Leakage inline diagnosis method in gas valve |
| CN209992134U (en) * | 2019-05-10 | 2020-01-24 | 华帝股份有限公司 | Device for detecting air tightness of torch valve body |
| CN111929114A (en) * | 2020-09-08 | 2020-11-13 | 南京分析仪器厂有限公司 | Petrochemical industry torch discharges on-line monitoring system of waste gas component and calorific value |
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