CN116593144A - Forced seal ball valve life test bed based on acoustic emission technology - Google Patents
Forced seal ball valve life test bed based on acoustic emission technology Download PDFInfo
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- G01M3/2876—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds for valves
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Abstract
The invention discloses a forced sealing ball valve life test bed and a life detection method, belonging to the field of pipeline valve component detection and life prediction research experiments, wherein the device comprises a constant-temperature liquid supply system, a constant-pressure gas supply system, a leakage detection system, an acoustic emission detection system and a measurement and control system; the constant temperature liquid supply system includes: the constant-pressure air supply system comprises a liquid medium storage tank, a liquid level sensor, a heat exchanger, a centrifugal pump, a temperature transmitter and a flowmeter, wherein the constant-pressure air supply system comprises: the leakage detection system includes: an air inlet end pressure transmitter, an air inlet end temperature transmitter and an air outlet end pressure transmitter; the acoustic emission detection system comprises an acoustic emission sensor and a clamp; the invention can realize the automatic control of the test bed and the automatic reading of the detection data, can automatically generate the service life test result of the tested forced sealing ball valve, solves the problem of manual leak detection at present, and can realize the real-time online detection of the leak rate of the forced sealing ball valve.
Description
Technical Field
The invention belongs to the field of pipeline valve component detection and life prediction research experiments, and particularly relates to a forced sealing ball valve life test bed and a detection method.
Background
With the high-speed development of energy and chemical industry production, the storage and transportation safety requirements of petroleum, natural gas and various production raw materials are gradually increased; the common pipeline in the storage and transportation system is used as a common pipeline transportation way in the storage and transportation system, the ball valve is used as a common pipeline control element in the field of chemical energy, and the sealing performance and the opening control performance of the ball valve are safe in production and transportation.
The forced sealing ball valve is a novel pipeline ball valve component, the novel ball valve utilizes a guide track on a valve rod to control the movement track of a ball body in the opening and closing process, so that a sealing pair and the valve body are free from contact and friction in the opening and closing process, the valve body and abrasion are weakened, the sealing pressure required by the valve is provided by the wedge-shaped structure of the ball body and the action of the valve rod, under the forward flow working condition, the sealing specific pressure is also provided by the medium pressure, but under the reverse flow working condition, the valve rod pressure is required to provide the sealing pressure and also is required to resist the medium pressure, so that the valve rod is easier to fatigue than a common ball valve, and the valve is easy to cause sealing failure due to frequent opening and closing in a high-pressure environment for a long time; in order to improve the performance index of the manufactured forced sealing ball valve, it is necessary to research the life prediction and the seal failure mechanism of the forced sealing ball valve, and an effective detection method and an experimental device for the accelerated life test and the internal and external leakage detection of the forced sealing ball valve are needed. The existing leak detection of the valve is also in the bubble method leak detection technology, the detection method has the problems of low detection efficiency, large detection result error, long test time and large number of testers, on the other hand, the existing life test device for the valve has the problems of manually reading data of each detection instrument and manually operating a test bed, larger data reading and control errors of a test system, and the existing measurement method for the forced seal detection of the inner leak rate and the outer leak rate needs special detection devices and detection steps, so that the valve to be detected can only be subjected to leak detection after the specified test device is installed, and the problem of difficulty in detecting the valve used in a pipeline is solved.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides an automatic forced sealing ball valve life test bed and an acoustic emission system detection method, which can realize automatic control of the test bed and automatic reading of detection data, can automatically generate life test results of a detected forced sealing ball valve, and solve the problem of manual leak detection at present. The acoustic emission detection method suitable for the test bed is also provided, and real-time online forced sealing ball valve leakage rate detection is realized.
In order to achieve the above purpose, the present invention adopts the following technical scheme.
A forced seal ball valve life test stand, the test stand comprising: the system comprises a constant-temperature liquid supply system, a constant-pressure air supply system, a leakage detection system, an acoustic emission detection system, a measurement and control system, an electric execution system of a valve to be measured and a forced sealing ball valve to be measured.
The constant-temperature liquid supply system is used for carrying out an accelerated life test by transporting the experimental liquid medium to the sealing surface of the forced sealing ball valve in a pressurized manner; the leakage detection system is used for measuring the leakage rate of the ball valve to be detected after the accelerated life test is completed; the acoustic emission system is used for collecting and recording acoustic wave changes generated by the ball valve to be tested in the test; the electric execution system measures the torque and the power of the valve to be tested and controls the valve to be tested to be opened and closed; the upper computer measurement and control system is used for collecting sensor signals of all systems in the test bed, converting the sensor signals into digital or image records, calculates and displays.
The constant temperature liquid supply system includes: the liquid medium storage tank, the liquid level sensor, the heat exchanger, the centrifugal pump, the temperature transmitter, the flowmeter, the liquid inlet end control valve and the liquid return end control valve, wherein the control port of the centrifugal pump is connected with the upper computer through the frequency converter, and the liquid inlet end is connected with the flange of the liquid medium storage tank. The centrifugal pump pumps out the liquid in the liquid storage tank, is connected with the tested forced sealing ball valve through the liquid inlet end control valve, is connected with the liquid return end control valve through the pipe, and finally returns to the liquid medium storage tank. Therefore, a liquid supply loop is formed, the temperature transmitter is used for detecting the medium temperature, the upper computer is used for controlling the liquid medium temperature through the heat exchanger by receiving the detection data of the temperature transmitter, and the liquid level sensor is used for monitoring the liquid level in the liquid medium storage tank.
The constant pressure air supply system includes: the air compressor outputs compressed air with determined pressure through the customized pressure reducing valve and is connected with a pipeline to form a constant-pressure air supply system.
The leak detection system includes: the device comprises an air inlet end stop valve, an air inlet end pressure transmitter, an air inlet end temperature transmitter, an air outlet end pressure transmitter and an air outlet end stop valve, wherein the air inlet end stop valve is connected with a constant pressure air supply system through a sealing valve cover and an air compressor connecting pipeline, the air inlet end pressure transmitter is connected with a three-way pipeline and then is connected with one end of a tested forced sealing ball valve through a flange, the air outlet end stop valve is connected with the air outlet end stop valve through the three-way pipeline, and the other end of the three-way pipeline is connected with the other end of the tested forced sealing ball valve.
The acoustic emission detection system comprises an acoustic emission sensor, a clamp and a preamplifier, wherein the acoustic emission sensor is fixed on a tested forced sealing ball valve through the clamp, the clamp provides pretightening force through a bolt, the acoustic emission sensor is connected with the preamplifier through a signal wire, and signals are transmitted to an upper computer through the preamplifier.
The measurement and control system consists of a control circuit, a signal acquisition card and an upper computer, wherein the control circuit is connected with a centrifugal pump, an air compressor, each stop valve and a tested forced sealing ball valve, the upper computer is used for controlling each part to execute on-off through the control circuit, the signal acquisition card is connected with each sensor and each transmitter, and data are sent to the upper computer after being processed.
The invention also provides a life test method for the forced sealing ball valve, which utilizes a test bed to carry out an accelerated life test on the forced sealing ball valve to be tested, and the specific method is as follows:
s11, after the forced sealing ball valve to be tested is visually detected and has no obvious defects of a valve body and a sealing pair and leakage points, the forced sealing ball valve to be tested is installed on a test position of a test bed, and a power line and a control line of the valve to be tested are connected into a measurement and control system through a lengthening cable;
s12, opening a forced sealing ball valve to be detected, closing a liquid inlet end control valve, a liquid return end control valve and an air outlet end stop valve, opening an air compressor, and conveying air into a pipeline of the leakage detection system. Meanwhile, the pressure transmitter at the air inlet end and the pressure transmitter at the air outlet end send data signals to a data acquisition card, and an upper computer continuously reads the signals and converts the signals into pressure readings;
s13, when inWhen the data signals of the air end pressure transmitter and the air outlet end pressure transmitter are stable, the upper computer controls to close the air inlet end stop valve and the air compressor. The upper computer collects and records the pressure P measured by the pressure transmitter at the air inlet end at the current moment, namely the moment T1 T1 feed And the pressure transmitter at the air outlet end measures the pressure P T1 out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected T1 feed And the temperature T measured by the pressure thermometer at the air outlet end T1 is output;
s14, after a fixed time interval delta T1, the upper computer collects and records the pressure P measured by the pressure transmitter at the air inlet end at the current moment, namely the moment T2 T2 feed And outlet end pressure transmitter P T2 out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected T2 feed And the temperature T measured by the pressure thermometer at the air outlet end T2 out
S15, the upper computer calculates delta t1 time interval according to the measured data, and the initial external leakage rate of the tested forced sealing ball valve is as follows:
；
s16, the upper computer controls to open the air outlet end stop valve, reduces the air pressure of the air outlet end to atmospheric pressure, then closes the air outlet end stop valve, and at the moment, the upper computer collects and records the pressure P measured by the air inlet end pressure transmitter at the current moment, namely the moment t0 t0 is advanced And the pressure transmitter at the air outlet end measures the pressure P t0 is out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected t0 is advanced And the temperature T measured by the pressure thermometer at the air outlet end t0 is taken out;
s17, after a fixed time interval delta t2, the upper computer records the pressure P measured by the pressure transmitter at the air inlet end at the current time t1 t1 is advanced And the pressure transmitter at the air outlet end measures the pressure P t1 is out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected t1 is advanced And the temperature T measured by the pressure thermometer at the air outlet end t1 is out;
s18, the upper computer calculates and obtains the initial internal leakage rate of the tested forced sealing ball valve within a delta t2 time interval according to the measured data:
；
s19, the upper computer records the initial inner leakage rate and the initial outer leakage rate as initial parameters of the tested forced sealing ball valve.
If the initial internal and external leakage rate of the forced sealing ball valve to be tested meets the standard, the accelerated life test can be continued, otherwise, the forced sealing ball valve to be tested needs to be replaced, and the steps S11-S18 are repeated until the initial internal and external leakage rate meets the standard;
s21, performing an accelerated life test on the forced sealing ball valve to be tested;
s211, the upper computer controls the air inlet end stop valve and the air outlet section stop valve to be closed, namely the leakage detection system is closed, the liquid inlet end control valve and the liquid return end control valve are opened, namely the liquid supply system is opened, the centrifugal pump is opened, the upper computer reads power data of the centrifugal pump and data signals of the flowmeter, the running power of the centrifugal pump is controlled through the frequency converter, the flow is stabilized near the designated liquid medium flow q, the upper computer reads the liquid medium temperature T measured by the temperature transmitter, and the liquid medium temperature T is controlled in a certain range through the heat exchanger;
s212, the upper computer controls the opening and closing of the tested forced sealing ball valve for a designated number of times N, and records the opening and closing moment of the tested forced sealing ball valve when each opening and closing is carried out;
s213, the centrifugal pump is recorded to be closed, and the upper computer controls to close the liquid inlet end control valve and the liquid return end control valve when all liquid media in the pipeline flow back into the liquid media storage tank;
s22, detecting and recording the current internal and external leakage of the forced sealing ball valve to be detected, wherein the detection method is the same as that of the steps S12-S8
S23, circularly repeating the steps S21-S22, and judging whether the forced sealing ball valve to be tested is completely in failure after each cycle, wherein the judging mode is as follows:
the external leakage rate of the valve to be tested exceeds A by the same way as the execution of the steps S13 and S14, and the external sealing failure of the valve to be tested can be judged; and (3) the internal leakage rate of the valve to be tested exceeds B by the same way as that of the steps S16 and S17, namely the internal sealing failure of the ball valve to be tested can be judged, and one of the internal leakage rate and the internal sealing failure can be judged to be the complete sealing failure of the forced sealing ball valve to be tested. And recording the total opening and closing times of the currently tested forced sealing ball valve.
Preferably, a life test of the forced sealing ball valve to be tested at different medium temperatures is carried out by using a test bed, and the specific modes are as follows:
s31, replacing the forced sealing ball valve to be tested, and performing steps S11-S18 to measure initial internal and external leakage rate
S32, the upper computer controls the air inlet end stop valve and the air outlet section stop valve to be closed, namely the leakage detection system is closed, the liquid inlet end control valve and the liquid return end control valve are opened, namely the liquid supply system is opened, the centrifugal pump is opened to read power data of the centrifugal pump and data signals of the flowmeter, the running power of the centrifugal pump is controlled through the frequency converter to enable the flow to be stabilized near the flow q of the appointed liquid medium, the upper computer controls the heat exchanger to heat or cool the liquid medium according to the set medium temperature based on signal feedback of the temperature sensor, and therefore the temperature medium is kept near the set temperature
S33, repeatedly executing the steps S21-S23, detecting whether the ball valve to be detected is completely invalid, and recording data in the upper computer
S34, changing the set liquid medium temperature, repeatedly executing the steps S31-S33, and testing the service life of the forced sealing ball valve to be tested under different liquid medium temperatures.
In addition, the invention also provides an acoustic emission detection method for the forced sealing ball valve, which predicts the internal and external leakage rate of the forced sealing ball valve to be detected by utilizing an acoustic emission technology, in the life test method of the forced sealing ball valve, every time the internal leakage rate and the external leakage rate of the forced sealing ball valve to be detected are measured, acoustic emission sensors arranged at two sides of the valve body of the forced sealing ball valve to be detected can collect time domain acoustic signals generated by leakage at the sealing part and the sealing pair of the valve body of the forced sealing ball valve to be detected under the current leakage environment, and the collected four-channel time domain acoustic signals are subjected to noise reduction and feature extraction, and then the internal and external leakage rate of the forced sealing ball valve to be detected is identified by utilizing a neural network, and the specific method is as follows:
s41, acquiring an acoustic emission signal in a fixed time interval under the current leakage detection of the forced sealing ball valve to be detected;
s42, noise reduction is carried out on the acquired acoustic emission signals;
s43, performing time-frequency conversion on the noise-reduced acoustic emission signals;
s44, performing feature sampling on the converted frequency domain acoustic emission signals, and extracting leakage rate features;
s45, identifying the leakage rate of the tested forced sealing ball valve by using the extracted leakage rate characteristics through a neural network model;
optionally, step S42 includes:
before measuring the leakage rate, collecting an environmental noise time domain sequence E (k) in a fixed time interval, setting d (k) =0 as a target output signal, namely a noise-free environment, and updating and adjusting a weight matrix w (k) for a plurality of times by repeating the following formulas (1), (2) and (3) to obtain an LMS filter applicable to the current environmental noise
In the above formula, μ is the filter convergence factor, the value is randomly generated, e (k) is the error signal sequence, w (k) is the weight matrix of the current filter, and w (k+1) is the filter weight matrix updated by iterative calculation.
And then the acoustic emission signal measured under the leakage detection is passed through an obtained LMS filter, so as to obtain the acoustic emission signal after active noise reduction.
Optionally, the step S13 comprises the following steps.
S51, carrying out Fourier transform on the acoustic emission signal subjected to noise reduction by the LMS filter;
s52, obtaining a discrete frequency domain acoustic emission signal A (k) from the continuous frequency domain signal obtained after Fourier transformation;
alternatively, the fourier transform expression used in step S21 is as follows:
。
in the above formula, a (w) is a frequency domain acoustic emission signal after fourier transform, F is fourier transform, a (t) is a time domain acoustic emission signal, w is frequency, and t is time.
Optionally, step S44 includes:
s61, selecting a frequency division signal group with the highest amplitude of the acoustic emission signal of the discrete frequency domain;
s62, calculating the frequency standard deviation, the mean square frequency and the center of gravity frequency of the discrete frequency domain acoustic emission signals.
S63, combining the characteristics to obtain the leakage rate characteristic.
Preferably, the neural network model involved in step S35 is a back propagation multi-layer perceptron model comprising input, hidden, and output layers with all inter-level neurons connected. The input layer comprises neuron numbers which are characteristic dimensions of input leakage rate, the output dimension of the input layer is the neuron numbers of the hidden layer 1, the output dimension of the hidden layer 1 is the neuron numbers of the hidden layer 2, the output dimension of the hidden layer 2 is the neuron numbers of the hidden layer 3, and the output layer only comprises one neuron and is used for calculating the inner leakage rate and the outer leakage rate of the forced sealing ball valve to be tested under the current working condition.
Compared with the prior art, the invention has the advantages that:
(1) The invention can adjust different working environments of the forced sealing ball valve, including working temperature and working medium, by utilizing the heat exchanger, so that the test bed can measure service life and sealing performance under different working environments.
(2) In the system of each part of the test bed, the execution mechanism and the sensor can be connected with the upper computer and the measurement and control system, so that the readings of the pressure transmitter, the temperature transmitter, the liquid level transmitter and the flowmeter can be automatically read in the whole test process, manual visual reading is not needed any more, in the accelerated life test, each step can be automatically executed and automatically detected, and whether the forced sealing ball valve to be tested is completely sealed and fails can be automatically judged, the test time of the life test is shortened, and the manpower is saved. Meanwhile, the error of manual reading is avoided.
(3) The invention is based on an acoustic emission detection system, and can automatically detect the acoustic emission signal in the valve under the current working environment of the forced sealing ball valve to be detected by utilizing the acoustic emission sensor and the clamp.
(4) The invention provides a life test method based on a test bed, which comprises an accelerated life test, an air tightness test and an acoustic emission test, and the life and the sealing performance of a tested forced sealing ball valve are measured from multiple aspects and angles.
Drawings
FIG. 1 is a schematic diagram showing the system components of a life test stand according to the present invention.
FIG. 2 is a schematic top view of the system components of the life test stand of the present invention.
FIG. 3 is a schematic view of the acoustic emission sensor and the clamp of the present invention.
FIG. 4 is a schematic diagram of a life test stand life detection flow according to the present invention.
FIG. 5 is a basic flow diagram of the acoustic emission detection method of the present invention.
FIG. 6 is a detailed flow chart of the acoustic emission detection method of the present invention.
Detailed Description
In order to make the technical solutions and advantages of the embodiments of the present invention more clear, the following will make the embodiments of the present invention clearly and completely described with reference to the accompanying drawings in the embodiments of the present invention. It will be apparent that the described embodiments are only some, but not all, embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1 and 2, an embodiment of the present invention discloses a life test stand for a forced seal ball valve, which includes: the device comprises a constant-temperature liquid supply system, a constant-pressure air supply system, a leakage detection system, an acoustic emission detection system, a measurement and control system, an electric execution system and a forced sealing ball valve to be tested.
The forced sealing ball valve to be tested in the embodiment belongs to a DN50 caliber forced sealing ball valve 0, an actuating mechanism of the valve is controlled by a motor, is connected with a measurement and control system by an RS485 signal wire, and is controlled to be opened and closed by a signal sent by an upper computer, and preferably, the motor actuating mechanism is also provided with an opening and closing moment measuring module and a power measuring module for monitoring the opening and closing actuating process of the forced sealing ball valve to be tested in the test process; furthermore, if the forced sealing ball valves with different calibers are measured, corresponding reducing flanges can be added at the two ends of the valve.
The constant temperature liquid supply system includes: the vertical liquid storage tank 1 is used for storing liquid media required by the operation of a test bed, a liquid inlet 2 and a liquid return 3 are formed in two sides of the liquid storage tank, in the embodiment, all pipelines adopt stainless steel seamless steel pipes with DN50 caliber as described in national standard GB/T8162-2008, the connection mode with other pipelines adopts DN50 and PN10 standard plate type flat welding flanges as described in national standard HG/T20592 2009, 304 stainless steel is adopted as a material, and a flange sealing surface adopts a protruding surface, so that the sealing specific pressure during connection can be increased, and the sealing performance is increased; in the embodiment, the back of the vertical liquid storage tank is also provided with an electronic magnetic turnover type liquid level meter 4, the electronic magnetic turnover type liquid level meter is connected with the vertical liquid storage tank through a pipeline, and the vertical liquid storage tank is also connected with a tubular heat exchanger and is used for controlling the temperature of liquid medium in the tank; the constant temperature liquid supply system further comprises a DN50 horizontal centrifugal pump 5, wherein the DN50 horizontal centrifugal pump is used for pumping liquid medium in the vertical liquid storage tank into the pipeline system of the test bed, a liquid inlet of the horizontal centrifugal pump 5 is connected with a liquid inlet end of the vertical liquid storage tank 1 through a flange, a liquid outlet of the horizontal centrifugal pump 5 is connected with a vertical pipeline 6 through a flange, and the vertical pipeline 6 is used for lifting liquid above the liquid level of the vertical liquid storage tank 1, so that the liquid medium in the pipeline can flow back into the vertical liquid storage tank 1 when the constant temperature industrial system stops working; in this embodiment, the vertical pipe 6 is connected with the liquid inlet straight pipe 101 through an elbow, the liquid inlet straight pipe 101 is provided with a thermometer for monitoring the temperature of the liquid medium pumped from the horizontal centrifugal pump 5, one end of the liquid inlet straight pipe 101 is connected with the flowmeter 7 through a flange, in this embodiment, a mass flowmeter is selected, the mass flowmeter has very high measurement precision for measuring the measured liquid medium, and the measurable fluid range is wide, so that the test bed meets the requirements of the test bed of the life-span test compatibility of the forced sealing ball valve to be measured in different medium environments. The other end of the flowmeter 7 is connected with a liquid inlet straight pipe 102, the liquid inlet straight pipe 102 is connected with a liquid inlet end control valve 8 according to the medium flowing direction, in the embodiment, a forced sealing ball valve with the same type and the same performance as a sealing ball valve to be tested is selected and used for correcting the test error caused by the self leakage of the valve in the leakage detection and accelerated life test. The other end of the liquid inlet end control valve 8 is connected with a liquid inlet bent pipe 104 through a bent pipe, the liquid inlet bent pipe 104 is respectively connected with a leakage test system and a liquid outlet straight pipe 105 in the follow-up direction of medium flow, the liquid return end control valve 9 is arranged, and the liquid outlet straight pipe 106 returns to the vertical liquid storage tank 1. In this embodiment, the liquid return end control valve 9 is a forced sealing ball valve with the same type and the same performance as the sealing ball valve to be tested, and is used for correcting the test error caused by the self leakage of the valve in the leakage detection and accelerated life test.
The constant pressure air supply system includes: the air compressor 10 is configured to provide gas pressure required in the leakage test system, in this embodiment, the air compressor 10 is a piston air compressor, and rated exhaust pressure is 2MPa, so that the test bed can perform leakage detection on forced seal ball valves of different models. Preferably, the air outlet of the air compressor 10 is connected with a one-way valve, so that when the air compressor stops working, the air in the pipeline of the test bed cannot flow back into the air compressor 10, and the safety of the air compressor is ensured; preferably, the air outlet of the air compressor 10 is also connected with a fixed-value pressure reducing valve, the fixed-value pressure reducing valve sets the outlet pressure value to 90% of the inlet pressure, and the fixed-value pressure reducing valve is used for ensuring that the high-pressure gas pressure is relatively stable when the constant-pressure gas supply system works to provide high-pressure gas pressure for the test pipeline and correcting the pressure fluctuation when the air compressor works; preferably, the power supply of the air compressor 10 is connected to a frequency converter, and the working power of the air compressor 10 is controlled by the frequency converter, so that the air compressor 10 is regulated to deliver air pressure to a test pipeline to reach a specified air pressure value; in the embodiment, the constant-value pressure reducing valve is connected with the sealing flange cover 11 through a high-pressure hose 12 through threads, and the sealing flange cover 27 is connected with the air inlet end stop valve 21 through a flange, so that the tightness of an air supply system is ensured.
The leak detection includes, in terms of gas flow direction: an air inlet end stop valve 21, a pressure and temperature integrated transmitter 22, an air inlet end connecting tee joint 23, an air outlet end connecting tee joint 24, a pressure and temperature integrated transmitter 25 and an air outlet end stop valve 26. In the present embodiment, the pressure-temperature integrated transmitter 22 and the pressure-temperature integrated transmitter 25 detect the pressure and the temperature of the air inlet chamber and the air outlet chamber of the leak detection system, respectively; preferably, the pressure and temperature integrated transmitters 22 and 25 are flange type diaphragm transmitters, the measuring range is 0-2 MPa, the measuring precision grade is 0.5MPa, and the pressure transmitters 22 and 25 are connected to a signal acquisition card through an RS485 communication protocol, so that the upper computer can conveniently read pressure signals. In this embodiment, the air inlet end stop valve 21 is used for controlling the pressure of the air inlet cavity, and isolating the constant temperature air supply system and the test pipeline, preventing the liquid from flowing into the constant pressure air supply system, and the air outlet end stop valve 26 is used for controlling the pressure of the air outlet end, and isolating the atmosphere and the test pipeline; preferably, the air inlet end stop valve 21 and the air outlet end stop valve 26 are forced sealing ball valves with the same type and the same performance as the sealing ball valve to be tested, and are used for correcting leakage detection and accelerated life test; preferably, the air inlet end stop valve 21 and the air outlet end stop valve 26 are connected with the control circuit by using an RS485 communication protocol to test errors caused by leakage of the valves. In the example, the air inlet end is connected with a tee joint for connecting a liquid inlet straight pipe 104 of a constant temperature liquid supply system, and the air inlet end of a leakage test system and a forced sealing ball valve to be tested; in this example, the air outlet end is connected with a tee joint for connecting the liquid inlet straight pipe 105 of the constant temperature liquid supply system, the air inlet and outlet end of the leakage testing system and the forced sealing ball valve to be tested.
The measurement and control system comprises: the upper computer, the control circuit and the signal acquisition card are preferably an industrial control computer carrying an RS485 communication protocol; preferably, the control circuit adopts a programmable controller PLC; preferably, the signal acquisition card is compatible with RS485 communication. Preferably, the measurement and control system communicates with other systems by RS485 communication.
As shown in fig. 1 and 3, the acoustic emission detection system includes: acoustic emission sensor 301, sensor clip 302, and pre-amplifier. In this example, the acoustic emission sensor 301 is disposed on a straight pipe section of the valve body, and is used for collecting acoustic emission signals emitted by the sealing ball valve to be tested when performing an inner leakage test and an outer leakage test; preferably, the selected acoustic emission sensor 301 should have a measurement range of 18KHz-200KHz, and the acoustic emission signal of the occurrence of a valve leak is primarily focused within this measurement range. The sensor clamp 302 is used for clamping and fixing the acoustic emission sensor 301 on the valve body of the forced sealing ball valve to be tested. Preferably, the clamp is of two half identical arch structures, the acoustic emission sensor 301 is placed in a reserved position in the middle of the structure, a middle hole is formed for leading out a signal wire of the acoustic emission sensor 301, two ears are led out from two ends of the clamp, and an upper hole is used for connecting the two half clamping structures through bolts and adjusting clamping force. The pre-amplifier is connected with a signal line of the acoustic emission sensor 301, filters and amplifies signals, and then is connected with an upper computer. In this example, the acoustic emission detection system includes two sets of sensors 302 and four sets of acoustic emission sensors 301, so as to form a four-channel acoustic emission acquisition system.
In this embodiment, as shown in fig. 4, a life test is performed on a forced sealing ball valve to be tested by using a test stand, and the specific method is as follows:
s11, after the forced sealing ball valve to be tested is visually detected and has no obvious defects of a valve body and a sealing pair and leakage points, the forced sealing ball valve to be tested is installed on a test position of a test bed, and a power line and a control line of the valve to be tested are connected into a measurement and control system through a lengthening cable;
s12, opening a forced sealing ball valve to be detected, closing a liquid inlet end control valve, a liquid return end control valve 9 and an air outlet end stop valve 26, opening an air compressor 10, and conveying air into a pipeline of the leakage detection system. Meanwhile, the pressure transmitter at the air inlet end and the pressure transmitter at the air outlet end send data signals to a data acquisition card, and an upper computer continuously reads the signals and converts the signals into pressure readings;
and S13, when the data signals of the air inlet end pressure transmitter 22 and the air outlet end pressure transmitter 25 are stable, the upper computer controls to close the air inlet end stop valve and the air compressor. The upper computer collects and records the pressure P measured by the pressure transmitter at the air inlet end at the current moment, namely the moment T1 T1 feed And the pressure transmitter at the air outlet end measures the pressure P T1 out Simultaneously collecting the temperature measured by the temperature transmitter at the air inlet endT T1 feed And the temperature T measured by the pressure thermometer at the air outlet end T1 is output;
s14, after a fixed time interval delta T1, the upper computer collects and records the pressure P measured by the pressure transmitter at the air inlet end at the current moment, namely the moment T2 T2 feed And outlet end pressure transmitter P T2 out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected T2 feed And the temperature T measured by the pressure thermometer at the air outlet end T2 out
S15, the upper computer calculates delta t1 time interval according to the measured data, and the initial external leakage rate of the tested forced sealing ball valve is as follows:
；
s16, the upper computer controls to open the air outlet end stop valve, reduces the air pressure of the air outlet end to atmospheric pressure, then closes the air outlet end stop valve, and at the moment, the upper computer collects and records the pressure P measured by the air inlet end pressure transmitter at the current moment, namely the moment t0 t0 is advanced And the pressure transmitter at the air outlet end measures the pressure P t0 is out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected t0 is advanced And the temperature T measured by the pressure thermometer at the air outlet end t0 is taken out;
s17, after a fixed time interval delta t2, the upper computer records the pressure P measured by the pressure transmitter at the air inlet end at the current time t1 t1 is advanced And the pressure transmitter at the air outlet end measures the pressure P t1 is out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected t1 is advanced And the temperature T measured by the pressure thermometer at the air outlet end t1 is out;
s18, the upper computer calculates and obtains the initial internal leakage rate of the tested forced sealing ball valve within a delta t2 time interval according to the measured data:
；
s19, the upper computer records the initial inner leakage rate and the initial outer leakage rate as initial parameters of the tested forced sealing ball valve.
If the initial internal and external leakage rate of the forced sealing ball valve to be tested meets the standard, the accelerated life test can be continued, otherwise, the forced sealing ball valve to be tested needs to be replaced, and the steps S11-S18 are repeated until the initial internal and external leakage rate meets the standard;
s21, performing an accelerated life test on the forced sealing ball valve to be tested;
s211, the upper computer controls the air inlet end stop valve and the air outlet section stop valve to be closed, namely the leakage detection system is closed, the liquid inlet end control valve and the liquid return end control valve are opened, namely the liquid supply system is opened, the centrifugal pump is opened, the upper computer reads power data of the centrifugal pump and data signals of the flowmeter, the running power of the centrifugal pump is controlled through the frequency converter, the flow is stabilized near the designated liquid medium flow q, the upper computer reads the liquid medium temperature T measured by the temperature transmitter, and the liquid medium temperature T is controlled in a certain range through the heat exchanger;
s212, the upper computer controls the opening and closing of the tested forced sealing ball valve for a designated number of times N, and records the opening and closing moment of the tested forced sealing ball valve when each opening and closing is carried out;
s213, the centrifugal pump is recorded to be closed, and the upper computer controls to close the liquid inlet end control valve and the liquid return end control valve when all liquid media in the pipeline flow back into the liquid media storage tank;
s22, detecting and recording the current internal and external leakage of the forced sealing ball valve to be detected, wherein the detection method is the same as that of the steps S12-S8
S23, circularly repeating the steps S21-S22, and judging whether the forced sealing ball valve to be tested is completely in failure after each cycle, wherein the judging mode is as follows:
the external leakage rate of the valve to be tested exceeds A by the same way as the execution of the steps S13 and S14, and the external sealing failure of the valve to be tested can be judged; and (3) the internal leakage rate of the valve to be tested exceeds B by the same way as that of the steps S16 and S17, namely the internal sealing failure of the ball valve to be tested can be judged, and one of the internal leakage rate and the internal sealing failure can be judged to be the complete sealing failure of the forced sealing ball valve to be tested. And recording the total opening and closing times of the currently tested forced sealing ball valve.
In the life test method of the forced sealing ball valve, when the internal leakage rate and the external leakage rate of the forced sealing ball valve to be tested are measured, the acoustic emission sensors arranged at two sides of the valve body of the forced sealing ball valve to be tested can collect time domain acoustic signals generated by leakage at the sealing part and the sealing pair of the valve body of the forced sealing ball valve to be tested in the current leakage environment, and the collected four-channel time domain acoustic signals are subjected to noise reduction and feature extraction, and then the internal leakage rate and the external leakage rate of the forced sealing ball valve to be tested are identified by using a neural network, and the specific method is as follows:
s11, acquiring an acoustic emission signal in a fixed time interval under the current leakage detection of the forced sealing ball valve to be detected;
s12, noise reduction is carried out on the acquired acoustic emission signals;
s13, performing time-frequency conversion on the noise-reduced acoustic emission signals;
s14, performing feature sampling on the converted frequency domain acoustic emission signals, and extracting leakage rate features;
and S15, identifying the leakage rate of the tested forced sealing ball valve by using the extracted leakage rate characteristics through a neural network model.
Optionally, step S12 includes:
before measuring the leakage rate, collecting an environmental noise time domain sequence E (k) in a fixed time interval, setting d (k) =0 as a target output signal, namely a noise-free environment, and updating and adjusting a weight matrix w (k) for a plurality of times by repeating the following formulas (1), (2) and (3) to obtain an LMS filter applicable to the current environmental noise
In the above formula, μ is the filter convergence factor, the value is randomly generated, and e (k) is the error signal sequence.
And then the acoustic emission signal measured under the leakage detection is passed through an obtained LMS filter, so as to obtain the acoustic emission signal after active noise reduction.
Optionally, step S13 includes:
s21, carrying out Fourier transform on the acoustic emission signal subjected to noise reduction by the LMS filter;
s22, obtaining a discrete frequency domain acoustic emission signal A (k) from the continuous frequency domain signal obtained after Fourier transformation;
alternatively, the fourier transform expression used in step S21 is as follows:
in the above formula, a (w) is a frequency domain acoustic emission signal after fourier transform, F is fourier transform, a (t) is a time domain acoustic emission signal, w is frequency, and t is time.
Optionally, step S14 includes:
s31, selecting a frequency division signal group with the highest amplitude of the acoustic emission signal of the discrete frequency domain;
s32, calculating the frequency standard deviation, the mean square frequency and the center of gravity frequency of the discrete frequency domain acoustic emission signals.
S33, combining the characteristics to obtain the leakage rate characteristic.
Preferably, the neural network model involved in step S15 is a back propagation multi-layer perceptron model comprising input, hidden, and output layers with all inter-level neurons connected. The input layer comprises neuron numbers which are characteristic dimensions of input leakage rate, the output dimension of the input layer is the neuron numbers of the hidden layer 1, the output dimension of the hidden layer 1 is the neuron numbers of the hidden layer 2, the output dimension of the hidden layer 2 is the neuron numbers of the hidden layer 3, and the output layer only comprises one neuron and is used for calculating the inner leakage rate and the outer leakage rate of the forced sealing ball valve to be tested under the current working condition.
Claims (10)
1. The forced sealing ball valve life test bed based on the acoustic emission technology is characterized by comprising a constant temperature liquid supply system, a constant pressure air supply system, a leakage detection system, an emission detection system, a measurement and control system, an electric execution system of a valve to be tested and a forced sealing ball valve to be tested, wherein the constant temperature liquid supply system is used for carrying out an accelerated life test by transporting a liquid medium for experiments to a sealing surface of the forced sealing ball valve in a pressurized manner; the constant-pressure air supply system is used for providing stable high-pressure air for the leakage test branch; the leakage detection system is used for measuring the leakage rate of the ball valve to be detected after the accelerated life test is completed; the acoustic emission system is used for collecting and recording acoustic emission signal changes generated by the ball valve to be tested in the test, and then sending the acoustic emission signals into the neural network after processing to obtain predicted inner and outer leakage rates; the measurement and control system is used for collecting sensor signals of all systems in the test bed, converting the sensor signals into digital or image records, calculating and displaying, and controlling motion components of all systems; the electric execution system is used for measuring the torque and the power of the valve to be tested and controlling the valve to be tested to be opened and closed.
2. The forced seal ball valve life test stand based on acoustic emission technology of claim 1, wherein the constant temperature liquid supply system further comprises: the liquid medium storage tank (1), the liquid level sensor (4), the heat exchanger, the centrifugal pump (5), the temperature transmitter, the flowmeter (6), the liquid inlet end control valve (8) and the liquid return end control valve (9), wherein the centrifugal pump control port (5) is connected with the upper computer through the frequency converter, and the liquid inlet end (2) is connected with the liquid medium storage tank (1) through a flange; the centrifugal pump (5) pumps out the liquid in the liquid medium storage tank (1) and is connected with the tested forced sealing ball valve through the liquid inlet end control valve (8), and then is connected with the liquid return end control valve (9) through the pipeline, and finally returns to the liquid medium storage tank (1) through the liquid return end (3), so that a liquid supply loop is formed, the temperature transmitter is used for detecting the medium temperature, and the liquid level sensor (4) is used for monitoring the liquid level in the liquid medium storage tank (1).
3. The forced sealing ball valve life test bed based on the acoustic emission technology, which is disclosed by claim 1, is characterized in that the constant-pressure air supply system comprises an air compressor (10) and a constant-value pressure reducing valve, and the air compressor (10) outputs the compressed air with the determined pressure through the constant-value pressure reducing valve.
4. The forced sealing ball valve life test stand based on the acoustic emission technology according to claim 1, wherein the leakage detection system comprises an air inlet end stop valve (21), an air inlet end pressure transmitter (22), an air inlet end temperature transmitter, an air outlet end pressure transmitter (25) and an air outlet end stop valve (26), the air inlet end stop valve (21) is connected with a constant pressure air supply system through a sealing valve cover (27) and an air compressor (10) connecting pipeline (12), the air inlet end pressure transmitter (22) is connected with a first tee pipe (23) and then connected with one end of a tested forced sealing ball valve (0) through a flange, the air outlet end stop valve (26) is connected with a second tee pipe (24), the other end of the second tee pipe (24) is connected with the air outlet end pressure transmitter (25), and the other end of the second tee pipe (24) is connected with the tested forced sealing ball valve (0).
5. The forced sealing ball valve life test bed based on the acoustic emission technology according to claim 1, wherein the acoustic emission detection system comprises an acoustic emission sensor (301), a clamp (302) and a preamplifier, the acoustic emission sensor (301) is fixed on the detected forced sealing ball valve through the clamp (302), the clamp provides pretightening force through a bolt, the acoustic emission sensor is connected with the preamplifier through a signal wire, and signals are transmitted to an upper computer through the preamplifier.
6. The forced sealing ball valve life test bed based on the acoustic emission technology according to claim 1, wherein the measurement and control system consists of a control circuit, a signal acquisition card and an upper computer, the control circuit is connected with a centrifugal pump (5), an air compressor (10), each stop valve and a tested forced sealing ball valve (0), the upper computer controls each part to execute on-off through the control circuit, the signal acquisition card is connected with each sensor and each transmitter, and data is sent to the upper computer after being processed.
7. The detection method for the life test bed of the forced sealing ball valve is characterized by using the test bed to detect leakage of the forced sealing ball valve to be detected, and comprises the following steps of:
s11, opening a forced sealing ball valve to be detected, closing a liquid inlet end control valve (8), a liquid return end control valve (9) and an air outlet end stop valve (26), opening an air compressor (10), and conveying air into a pipeline of the leakage detection system; meanwhile, the pressure transmitter (22) at the air inlet end and the pressure transmitter (25) at the air outlet end send data signals to a data acquisition card, and an upper computer continuously reads the signals and converts the signals into pressure readings;
s12, when data signals of the air inlet end pressure transmitter (22) and the air outlet end pressure transmitter (25) are stable, the upper computer (403) controls to close the air inlet end stop valve (21) and the air compressor (10); the upper computer collects and records the pressure P measured by the pressure transmitter at the air inlet end at the current moment, namely the moment T1 T1 feed And the pressure transmitter at the air outlet end measures the pressure P T1 out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected T1 feed And the temperature T measured by the pressure thermometer at the air outlet end T1 out ；
S13, after a fixed time interval delta T1, the upper computer collects and records the pressure P measured by the air inlet end pressure transmitter (22) at the current moment, namely the moment T2 T2 feed And the pressure P measured by the pressure transmitter (25) at the air outlet end T2 out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected T2 feed And the temperature T measured by the pressure thermometer at the air outlet end T2 out ；
S14, calculating the external leakage rate S of the tested forced sealing ball valve within a time interval delta t1 by the upper computer according to the measured data External leakage The method comprises the following steps:
；
s15, the upper computer controls to open the air outlet end stop valve, reduces the air pressure of the air outlet end to the atmospheric pressure, then closes the air outlet end stop valve (26), and at the moment, the upper computer collects and records the pressure P measured by the air inlet end pressure transmitter (22) at the current moment, namely the moment t0 t0 is advanced And the pressure P measured by the pressure transmitter (25) at the air outlet end t0 is out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected t0 is advanced And the temperature T measured by the pressure thermometer (29) at the air outlet end t0 is taken out;
s16, throughAfter a fixed time interval delta t2, the upper computer records the pressure P measured by the pressure transmitter (22) at the air inlet end at the moment t1 t1 is advanced And the pressure P measured by the pressure transmitter (25) at the air outlet end t1 is out At the same time, the temperature T measured by the temperature transmitter at the air inlet end is collected t1 is advanced And the temperature T measured by the pressure thermometer at the air outlet end t1 is out;
s17, calculating by the upper computer according to the measured data to obtain the leakage rate S in the tested forced sealing ball valve within the time interval delta t2 Internal leakage The method comprises the following steps:
。
8. the method for detecting the service life of the forced sealing ball valve to be detected by using a test bed according to claim 7, wherein the method comprises the following steps:
s21, an upper computer controls an air inlet end stop valve (21) and an air outlet end stop valve (26) to be closed, namely, a leakage detection system is closed, a liquid inlet end control valve (8) and a liquid return end control valve (9) are opened, namely, a liquid supply system is opened, a centrifugal pump (5) is opened, the upper computer reads power data and flow meter data signals of the centrifugal pump (5), the running power of the centrifugal pump (5) is controlled through a frequency converter, so that the flow is stabilized near a designated liquid medium flow q, and the upper computer reads a liquid medium temperature T measured by a temperature transmitter (15) and is controlled in a certain range by a heat exchanger (4);
s22, the upper computer controls the forced sealing ball valve to be tested to be opened and closed for a designated number of times N, and the opening and closing moment of the forced sealing ball valve to be tested is recorded when each opening and closing is performed;
s23, recording and closing the centrifugal pump, waiting for all liquid medium in the pipeline to flow back into the liquid medium storage tank (1), and controlling and closing a liquid inlet end control valve (8) and a liquid return end control valve (9) by the upper computer;
s24, detecting and recording the current internal and external leakage of the forced sealing ball valve to be detected, wherein the detection method is the same as that of the steps S11-S17;
s25, circularly repeating the steps S21-S24, judging whether the forced sealing ball valve to be tested is completely in sealing failure after each cycle, and judging that the external sealing failure of the valve to be tested is caused by the fact that the external leakage rate of the valve to be tested exceeds A in the mode of executing the steps S13 and S14; the internal leakage rate of the valve to be tested exceeds B% by executing the steps S16 and S17, namely the internal sealing failure of the ball valve to be tested can be judged, and the complete sealing failure of the forced sealing ball valve (0) to be tested can be judged by either one of the internal leakage rate and the internal sealing failure; and recording the total opening and closing times of the currently tested forced sealing ball valve.
9. The detection method for the forced sealing ball valve is suitable for the detection method of claim 7, and is characterized in that the acoustic emission sensor is used for predicting the internal leakage rate and the external leakage rate of the forced sealing ball valve to be detected, and the specific method is as follows:
s31, acquiring an acoustic emission signal in a fixed time interval under the current leakage detection of the forced sealing ball valve to be detected;
s32, noise reduction is carried out on the acquired acoustic emission signals;
s33, performing time-frequency conversion on the noise-reduced acoustic emission signals;
s34, performing feature sampling on the converted frequency domain acoustic emission signals, and extracting leakage rate features;
and S35, identifying the leakage rate of the tested forced sealing ball valve by using the extracted leakage rate characteristics through a neural network model.
10. The method according to claim 9, wherein step S32 includes:
before measuring the leakage rate, collecting an environmental noise time domain sequence E (k) within a fixed time interval, setting d (k) =0 as a target output signal, namely, a noise-free environment, and updating and adjusting a weight matrix w (k) for a plurality of times by the following loop iteration calculation formulas (1) (2) (3) to obtain an LMS filter applicable to the current environmental noise
，
Wherein mu is the convergence factor of the filter, the value is randomly generated, e (k) is an error signal sequence, y (k) is an output signal, w (k) is the weight matrix of the current filter, and w (k+1) is the weight matrix of the filter after iterative computation and updating;
step S33 includes:
s41, carrying out Fourier transform on the acoustic emission signal subjected to noise reduction by the LMS filter;
s42, obtaining a discrete frequency domain acoustic emission signal A (k) from the continuous frequency domain signal obtained after Fourier transformation;
the fourier transform expression used in step S21 is as follows:
，
in the formula, A (w) is a frequency domain acoustic emission signal subjected to Fourier transform, F is Fourier transform, a (t) is a time domain acoustic emission signal, w is frequency, t is time, i is an imaginary factor, and e is a natural logarithm;
step S34 includes:
s51, selecting a frequency division signal group with the highest amplitude of the acoustic emission signal of the discrete frequency domain;
s52, calculating the frequency standard deviation, the mean square frequency and the center of gravity frequency of the discrete frequency domain acoustic emission signals;
s53, combining the characteristics to obtain leakage rate characteristics;
in step S35, the neural network model is a counter-propagating multi-layer perceptron model, and the model includes an input layer, a hidden layer 1, a hidden layer 2, a hidden layer 3, and an output layer, all connected with neurons between layers.
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