The intelligent calibration equipment of a kind of low redundance high-reliability safety valve
One, technical field
The utility model relates to a kind of intelligent calibration equipment of low redundance high-reliability safety valve, belong to pressure-bearing special equipment detection technique field, specifically relate to the opening pressure scope at 0.1Mpa ~ 42Mpa, medium is the testing device of safety valve on pressure vessel, pressure pipeline and the plant equipment of air, water vapor, water and other chemical substances.
Two, background technology
In recent years, along with the fast development of national economy, the demand of oil, industrial chemicals is increased considerably, the petrochemical complex industry obtains fast development, and the process units scale is increasing, and working depth is constantly deepened.The petrochemical complex industry plays an important role in national economy, is one of mainstay industry of China's economic development.Safety valve is a kind of intelligent valve, does not utilize the power of system media itself to discharge the fluid of a load quantity by any external force, to prevent the over proof safety value of pressure.After pressure recovered normally, valve again row was closed and is stoped medium to continue to flow out.Safety valve as the safety attachment of special equipment, is to guarantee petroleum chemical enterprise's pressure vessel and pressure pipeline safety, prevents the last resort of major accident.The security of petrochemical valve is normally operated on high temperature, the high-tension apparatus, medium mostly is poisonous, harmful, inflammable, explosive medium, under physics, the chemical factor effects such as on-stream pressure, temperature, medium cleanliness factor and surrounding medium corrosion, safety valve performance particularly opening pressure and sealing property can change, safety valve in accordance with regulations opened by pressure or time seat be will cause, production safety hidden danger and environmental pollution caused.
Regulation " Annual Test of Safty Valves, general every year at least one times " according to TSG ZF001-2006 " safety valve safety and technical supervision rules " B6.3.1 bar.The periodic check of safety valve comprises opening pressure and sealing load test.Opening pressure of safety valve refers to the predetermined pressure that safety valve begins to open under service condition, under this pressure, the power that makes valve opening that is produced by pressure medium under the service condition of regulation is also referred to as opening pressure or set-pressure usually with making flap remain on the mutual balance of power on the valve seat.Safety valve is divided into two kinds of complete opening type and micro-open types; micro-open type refers to that the Lift of flap is 1/40 ~ 1/20 of valve seat larynx footpath; complete opening type refers to that the Lift of flap is 1/4 of valve seat larynx footpath; the acting characteristic of safety valve has very large difference thus; the acting characteristic of fall lift safety valve belongs to two sections action types; Low lift safety valve is circular arc type, only has the discharge capacity of qualified breakdown action characteristic guarantee safety valve, and then prevents protected equipment superpressure destruction.The static pressure of safety valve import when sealing load refers to carry out leakage test is measured the slip by the closing member sealing surface under this pressure.
The mode that current safety valve off-line verification is adopted mainly is the checking table verification, and what the most checking table was installed all is analogue instrument.Such verification mode Main Problems is:
1) precision of analogue instrument is generally lower, and the analogue instrument precision of at present safety valve testing employing is 0.4 grade, can't accomplish high-acruracy survey;
2) adopt single analogue instrument can't compare measurement, when instrument breaks down, can not get correct measurement data;
3) adopt analogue instrument to need operating personnel's reading, when requiring operating personnel near force value reaches set-pressure, sound when opening according to safety valve, read the front top pressure of force value retrace, and this force value occurs and the time of maintenance is very short, and operating personnel are difficult to catch and precisely read;
4) use the whole force value change curve of analogue instrument in can't record security valve checking procedure, the related data in the checking procedure, form all need operating personnel's hand filling.
Growth along with the petrochemical complex industry, annual censorship safety valve quantity is also more and more, the inspection technology document of tested safety valve is by manually filling in, anomalous differences appears in the simulated pressure table that how to prevent conventional off-line checking table, improve verification opening pressure precision, avoid artificial reading and the contingent mistake of the qualified opening pressure of judgement in the safety valve testing, and then the verification accuracy rate and the efficient that improve safety valve is each management organization, inspection body and applying unit institute questions of common interest, and the Research Significance of the intelligent calibration equipment of safety valve is great.
Three, utility model content
1, the utility model purpose: the purpose of this utility model is to provide the intelligent calibration equipment of a kind of low redundance high-reliability safety valve and method of calibration, break traditions calibration equipment by artificial reading, judge, record and the lower present situation of accuracy of detection, propose to use simultaneously the high-precision pressure transmitter of two same sizes, utilize computer to make separately pressure history, mutually compare, further improve the reliability of its measurement, realized the low redundance of safety valve offline inspection, high reliability and intellectuality, can improve verification accuracy rate and the efficient of safety valve, financial cost is saved in the ensure safety safe operation of valve.
2, the purpose of this utility model is to realize by following technical scheme:
The intelligent calibration equipment of a kind of low redundance high-reliability safety valve, comprise safety valve (1), verification platform (2), on the suction side flange (3), high-voltage tube (4), video monitoring equipment (5), security protection wall (6), source of the gas (12), gas cylinder (13), compressor (14), accumulator (15), outlet side flange (16), outlet (17), tank (18), back-up valve (21) on pure water (19) and the control desk (20) and blowdown valve (22), its feature is also comprising the pressure unit (7) of two same sizes with this device, output signal line (8), data acquisition board (9), serial port data line (10), panel computer and software (11), wherein safety valve (1) is erected on the verification platform (2), the suction flange of safety valve (1) bottom down, on the suction side flange (3) is connected with the suction flange of safety valve (1) bottom, outlet side flange (16) is connected with the discharge flange of safety valve (1), one end of outlet (17) is connected with outlet side flange (16), the other end is connected in the pure water (19) of tank (18), one end of the first high-voltage tube (4) is connected with on the suction side flange (3), the middle part is opened 2 holes and is connected with the pressure unit (7) of two same sizes, the other end passes security protection wall (6) and is connected with control desk (20), output signal line (8) one ends are connected with pressure unit (7), the other end is connected with data acquisition board (9), data acquisition board (9) connects panel computer (11) by serial port data line (10), back-up valve (21) and blowdown valve (22) are installed respectively in the bottom of control desk (20), one side of accumulator (15) is connected with control desk (20) by the second high-voltage tube (4), opposite side is connected with compressor (14) by third high pressure pipe (4), compressor (14) one sides are connected with gas cylinder (13) by the 4th high-voltage tube (4), check is housed with source of the gas (12), at tank (18) top installation-video monitoring equipment (5) in the gas cylinder (13).
On the suction side flange 3 in the intelligent calibration equipment of above-mentioned low redundance high-reliability safety valve adopts hydraulic clamps to clamp with verification platform 2 to be connected, and the hydraulic clamp clamping force can be regulated, and the centre pad that adds high pressure is guaranteed to seal; High-voltage tube 4 all adopts with on the suction side flange 3, outlet side flange 16, pressure unit 7, accumulator 15, compressor 14 and gas cylinder 13 and is threaded; Video monitoring equipment 5 is installed in the top of the outlet side leakage test tank 18 of safety valve 1, the number of bubbles in the time of can the clear view impermeability test in the tank 18; Verification is provided by gas cylinder 13 with source of the gas 12, is stored in the accumulator 15 after compressed machine 14 compressions, and the system demand pressure height is controlled by the back-up valve 21 on the control desk 20 and blowdown valve 22; Security protection wall 6 is to make with reinforced concrete, the high 2100mm of wall, thick 300mm.
The intelligent calibration equipment of above-mentioned low redundance high-reliability safety valve, its feature with described panel computer (11) in comprise pressure acquisition system module and unlatching value analysis and Control program module.
The method of using the intelligent calibration equipment of above-mentioned low redundance high-reliability safety valve to carry out verification, its checking procedure is as follows:
A, with the import and export of safety valve to be verified (1) before connecting with clean-out system clean, decontamination;
B, macro check safety valve (1) check that whether its parts are intact, have flawless, corrosion and mechanical damage;
C, by security protection wall (6), formulate perfect security system, verification equipment region and manually-operated zone isolation are opened, operating personnel operate outside security protection wall (6), observe by the film viewing screen of video monitoring equipment (5);
D, the source of the gas (12) that provided by gas cylinder (13) after compressor (14) compression, fill source of the gas (12) pressure accumulation by third high pressure pipe (4) through the 4th high-voltage tube (4) in accumulator (15);
After unmanned behind e, the affirmation security protection wall (6), prepare the beginning test operation;
F, open the back-up valve (21) on the control desk (20), make the source of the gas (12) of accumulator (15) enter safety valve (1) by the first high-voltage tube (4);
G, slow the raise intake pressure of safety valve (1), be elevated to opening pressure 90% after, the rate of rise should not be higher than the opening pressure of per second 1%;
Safety valve (1) intake pressure curvilinear motion in h, observation panel computer and the software (11), according to opening criterion, change to setting value when measuring pressure curve curvature, and force value negative growth, automatically point pressure is pressure this moment before the negative increment of record, and reporting operating personnel to confirm, operating personnel hear that unlatching sound is normal, confirm that pressure is the opening pressure of safety valve (1) this moment;
After j, verification are complete, by the blowdown valve (22) on the control desk (20) with the steady pressure release of pressure of safety valve (1) to zero-bit, on the suction side flange (3) and outlet side flange (16) that dismounting connects.
K, the safety valve (1) good to verification are hung approval plate, lead sealing, are provided calibration tails and verification report.
Pressure curve among the above-mentioned steps h is by following method the data of the pressure unit (7) of two same sizes to be carried out error identification and normalized, and judges that by the opening pressure of verification safety valve its method step is as follows:
1) pressure unit of two same sizes (7) is transferred to respectively data acquisition board (9) with current signal, panel computer and software (11) (9) two pressure units of receive data collection plate (7) analog to digital conversion result, automatically data of two points corresponding to each sampling instant on two pressure histories of point-by point comparison, if two pressure data relative errors that each sampling instant obtains less than or equal to 0.4% group number super account for total group several more than 85%, think that then safety valve intelligent checking device whole system is normal, reliably, this time the experimental measurement data are true, effectively, removing may be because of after transient electromagnetic disturbs two pressure data relative errors causing greater than 0.4% group number, again the force value of each sampling instant is taken as the mean value of the data of these moment two points, forms new curve: be this pressure test and checking curve;
2) if two pressure data relative errors that each sampling instant obtains organize several 40% less than or equal to 0.4% group number less than total, need then to check whether safety valve intelligent checking device whole system is normal, especially need to check whether pressure pipeline has gas leakage, whether two pressure units are airtight reliable with being connected of pipeline, check completely to measure again;
3) in panel computer and software (11), set safety valve (1) type and unlatching criterion before the verification, safety valve unlatching criterion is as follows: when safety valve (1) type of verification is complete opening type, when the pressure curve curvature value less than-1, and force value negative growth, automatically point pressure is pressure this moment before the negative increment of record, and report operating personnel to confirm, operating personnel hear that unlatching sound is normal, confirm that pressure is qualified opening pressure this moment, when safety valve (1) type of verification is micro-open type, the pressure curve curvature value turns to and is negative value, and the force value negative growth, automatically point pressure is pressure this moment before the negative increment of record, and reports operating personnel's affirmation, operating personnel hear that unlatching sound is normal, confirm that pressure is qualified opening pressure this moment.
The principle that the intelligent calibration equipment of above-mentioned low redundance high-reliability safety valve carries out verification is as follows:
Pressure curve is connected in by two that same size pressure unit 7 is transferred to respectively data data acquisition board 9 with current signal in the high-voltage tube 4, the analog to digital conversion result of panel computer and 9 two pressure units 7 of software 11 receive data collection plates and carry out error identification and normalized after convert corresponding force value to and consist of, in panel computer and software 11, select safety valve 1 type before boosting, when safety valve 1 type of verification is complete opening type, curvature deflects into setting value, and force value negative growth, automatically point pressure is pressure this moment before the negative increment of record, and report operating personnel to confirm, operating personnel hear that unlatching sound is normal, confirm that pressure is qualified opening pressure this moment, when safety valve (1) type of verification is micro-open type, curvature deflects into setting value, and the force value negative growth, automatically point pressure is pressure this moment before the negative increment of record, and reports operating personnel's affirmation, operating personnel hear that unlatching sound is normal, confirm that pressure is qualified opening pressure this moment.
3, beneficial effect
A. the intelligent calibration equipment of low redundance high-reliability safety valve of the present utility model has adopted Electric automation technology, substitute traditional high-precision analog tensimeter (levels of precision 0.4%) with high-precision pressure transmitter (levels of precision 0.075%), so that whole device levels of precision reaches 0.175%.
. its method of calibration is based upon on the basis of mathematical simulation, core is the pressure unit that connects 2 same sizes in the verification pipeline straight length of safety valve inflow point, guarantee that pressure reduces to minimum, the data result of the pressure unit of 2 same sizes is carried out converting corresponding force value to after error identification and the normalized, and then be depicted as pressure curve, guarantee that the force value that gathers is accurately credible, have accurate self-checking capability.
C. inserted the unlatching interpretational criteria of formulating according to the different acting characteristics of low redundance high-reliability safety valve in the software, testing result is reliable, has broken traditional method of calibration, improves verification accuracy rate and the efficient of safety valve.
Four, description of drawings
Fig. 1: the structural representation of the intelligent calibration equipment of low redundance high-reliability safety valve;
Reference numeral: 1-safety valve, 2-verification platform, 3-on the suction side flange, 4-high-voltage tube, 5-video monitoring equipment, 6-security protection wall, 7-pressure unit, 8-output signal line, 9-data acquisition board, 10 serial port data lines, 11-panel computer and software, 12-source of the gas, 13-gas cylinder, 14-compressor, 15-accumulator, 16-outlet side flange, 17-outlet, 18-tank, 19-pure water, 20-control desk, 21-back-up valve, 22-blowdown valve.
Fig. 2: pressure acquisition system hardware structure diagram;
Fig. 3: pressure acquisition system software module.
Fig. 4: unlatching value analysis and Control programmed software module.
Five, embodiment
Embodiment 1, the intelligent calibration equipment of low redundance high-reliability safety valve consist of be connected as follows:
Fig. 1 is the structural representation of device of the present utility model, according to shown in Figure 1, on safety valve 1 setting and the verification platform 2, suction flange down, on the suction side flange 3 adopts hydraulic clamp to be connected with the suction flange of safety valve 1 bottom, the centre pad that adds high pressure, one end of the first high-voltage tube 4 is threaded with on the suction side flange 3, open the air-path interface of two 1/2NPT at the first high-voltage tube 4, the pressure unit 7 that to connect 2 specifications be Rosemount 2051T, the circular hole that the other end passes security protection wall 6 is threaded with control desk 20, back-up valve 21 and blowdown valve 22 are housed on the control desk 20, output signal line 8 one ends are connected with pressure unit 7, the other end is connected with data acquisition board 9, data acquisition board 9 connects panel computer and software 11 by serial port data line 10, in panel computer and software 11 installations and the T3 of the Malata panel computer, one side of accumulator 15 is connected with control desk 20 by the second high-voltage tube 4, opposite side is connected with compressor 14 by third high pressure pipe 4, compressor 14 1 sides are connected with gas cylinder 13 by the 4th high-voltage tube 4, opposite side is connected with accumulator 15 by high-voltage tube 4, outlet side flange 16 connection outlets 17 at safety valve 1, outlet 17 is positioned over tank 18, and guarantee that pure water 19 floods outlet 17 fully, high-voltage tube 4 and gas cylinder 13, compressor 14, accumulator 15 and control desk 20 all are threaded, outlet side flange 16 adopts with outlet 17 and is threaded, check being housed with source of the gas 12 in the gas cylinder 13, is video monitoring equipment 5 above safety valve 1 discharge flange.Other concrete specifications and models have:
1, safety valve 1 be the opening pressure scope at 0.1Mpa ~ 42Mpa, medium is the low redundance high-reliability safety valve on pressure vessel, pressure pipeline and the plant equipment of air, water vapor, water and other chemical substances.
2, verification platform 2 materials are that stainless steel 304, length and width height are 1500 * 800 * 800mm.
3, high-voltage tube 4 and outlet 17 are 316ss, and external diameter is 15mm, and wall thickness is 1.8mm.
4, video monitoring 5 is installed in 2m place, tank 18 top, and model is CA-KS30NE.
5, source of the gas 12 is the nitrogen of 99.9% purity, and gas cylinder 13 is volume 40L, the ordinary nitrogen bottle of nominal pressure 15Mpa.
6, compressor 14 models are general auspicious Gus PGN42-0.35.
7, accumulator 15 volume 500L, material is 16MnR, maximum working pressure (MOP) 50MPa.
8, control desk 20 models are Shanghai Ke Feng SAT-Q.
9, back-up valve 21 and blowdown valve 22 are SUPERTEK model 30-11HF9.
10, tank 18 is long 400mm, wide 300mm, and high 300mm, thickness of slab are the stainless steel trough of 2mm.
11, hydraulic clamp, model are KHXT-20, clamping force 300-150000N, stroke 30-100mm.
12, high-pressure spacer is teflon gasket, according to pressure different choice different-thickness.
13, output signal line 8 is the KVVP2 shielded cable.
14, data acquisition board 9, serial port data line 10 are by consisting of as shown in Figure 2.
15, panel computer and software 11 are made of Fig. 3 pressure acquisition system software module, Fig. 4 unlatching value analysis and Control programmed software module.
As shown in Figure 2, the sampling resistor network that the 4-20mA current signal of pressure unit 7 outputs forms through the precision resister by 100R, the access model is the X0 of the analog switch of CD4051, the X1 end, analog switch outputs to the AIN1 end of AD by the X end, and pass through MUX2A, MUX2B, MUX2C port and single-chip microcomputer carry out alternately, the AD model is AD7705, the single-chip microcomputer model is MSP430, AD and single-chip microcomputer are undertaken alternately by port ADDOUT and ADDIN, single-chip microcomputer is connected the result that AD changes serial ports 232 communications with the touch-control input and shows that alternately touch-control input and demonstration are in the T3 of the Malata panel computer by TXD with RXD.
The pressure acquisition system software module as shown in Figure 3, setting up procedure a begins to gather pressure data, then carries out step b, do not meet 0.15% requirement such as error, then carry out the step c end that reports an error, meet the requirements such as error and then carry out steps d, then carry out step e, as reach 50% of opening pressure, and carry out step f, do not reach and continue step e judgement, when reaching step g, pressure requires 90% of opening pressure, carry out step h, otherwise continue step g, carry out step I by operating personnel at last and finish to gather.
Unlatching value analysis and Control programmed software module as shown in Figure 4, at first carry out step a and select low redundance high-reliability safety valve, then carry out step b and gather pressure data, carrying out step c according to step b data calculates, then carry out steps d and judge qualified opening pressure section according to the unlatching criterion of low redundance high-reliability safety valve, then carry out step e, the negative increment of inquiry pressure in qualified opening pressure section, obtain first negative point of increase, obtain the opening pressure value with step f, carry out step g prompting user save data.Turn-on data is sent to and is provided reporting system, provides reporting system not in this utility model content.