CN115200804A

Movatterモバイル変換

Info

Publication number: CN115200804A
Application number: CN202110393877.1A
Authority: CN
Inventors: 黎远中; 罗飞飞; 吴芳芳; 李仁源; 杨文文; 蒋建武; 祁治中; 崔德耀; 白璐
Original assignee: Xinjiang Xinte Crystal Silicon High Tech Co ltd; Xinte Energy Co Ltd
Current assignee: Xinjiang Xinte Crystal Silicon High Tech Co ltd; Xinte Energy Co Ltd
Priority date: 2021-04-13
Filing date: 2021-04-13
Publication date: 2022-10-18

Abstract

Translated fromChinese

本发明公开了一种安全阀在线检测系统及检测方法，该系统包括：介质储存单元用于储存安全阀检测用介质；输送管路与介质存储单元连接；空腔通过输送管路与介质储存单元连接，空腔入口通过输送管路与介质储存单元连接，空腔第一出口用于与待检测的安全阀进口连接；第一阀门设置于介质储存单元与空腔之间的输送管路上；第二阀门设置于空腔第二出口的连接管路上；第一压力检测单元用于检测空腔内的介质压力并发送给控制单元；控制单元用于通过调节第一阀门、第二阀门来控制空腔内的压力为预设压力，对安全阀进行在线启跳压力、密封试验的检测。该系统及方法检测精确度高，误差因素减至最小。通过选用精度等级高的仪器、合理标定检测仪提高检测准确度。

The invention discloses an on-line detection system and a detection method for a safety valve. The system comprises: a medium storage unit for storing a medium for detection of a safety valve; a conveying pipeline is connected with the medium storage unit; a cavity is connected to the medium storage unit through the conveying pipeline connection, the cavity inlet is connected with the medium storage unit through the conveying pipeline, and the first outlet of the cavity is used to connect with the inlet of the safety valve to be detected; the first valve is arranged on the conveying pipeline between the medium storage unit and the cavity; Two valves are arranged on the connecting pipeline of the second outlet of the cavity; the first pressure detection unit is used to detect the medium pressure in the cavity and send it to the control unit; the control unit is used to control the air pressure by adjusting the first valve and the second valve The pressure in the cavity is the preset pressure, and the online tripping pressure and sealing test are tested for the safety valve. The system and method have high detection accuracy and minimize error factors. The detection accuracy is improved by selecting instruments with high precision and rationally calibrating the detector.

Description

Translated fromChinese

安全阀在线检测系统及检测方法Safety valve online detection system and detection method

技术领域technical field

本发明属于安全阀检测技术领域，具体涉及一种安全阀在线检测系统及检测方法。The invention belongs to the technical field of safety valve detection, and in particular relates to an online detection system and a detection method of a safety valve.

背景技术Background technique

随着科学技术的不断进步，现代化企业生产规模逐步扩大，石油、化工、能源等行业的生产装置迈向大型化方向发展，安全和环保的要求也越来越高，而目前大多数压力设备上的安全阀采用离线校验，离线校验要经过拆卸、运输、校验、安装的环节，特别是大直径的安全阀采取离线校验，其检测周期长、费用较高。With the continuous progress of science and technology, the production scale of modern enterprises has gradually expanded, the production equipment in the petroleum, chemical, energy and other industries is developing towards large-scale development, and the requirements for safety and environmental protection are getting higher and higher. Off-line verification is adopted for the safety valve of large diameter, and the off-line verification needs to go through the links of disassembly, transportation, verification and installation, especially the large-diameter safety valve adopts off-line verification, which has a long detection period and high cost.

至今几乎所有商用在线检测安全阀技术的核心，利用液压油缸夹紧或者气动夹紧安全阀的阀杆，促使安全阀的阀芯开启,判断开启状态的同时，利用计算机数据采集系统进行检测,实现不拆卸安全阀的现场检测。The core of almost all commercial on-line detection safety valve technology so far is to use hydraulic cylinder to clamp or pneumatically clamp the valve stem of the safety valve to prompt the valve core of the safety valve to open. On-site inspection without dismantling the safety valve.

现有商用的安全阀在线校验仪主要由机械夹具、液压动力单元和数据采集处理单元三部分组成，其中，机械夹具主要针对安全阀进行夹紧和定位，为液压系统提供一个外力执行器，根据安全阀规格不同，准备有各种不同规格尺寸的夹具。机械夹具采用组合式结构，拆装方便、安全可靠。液压动力单元主要由手动/自动泵组成，可提供可调节的液压输出和流量，用以控制外加的提升力和提升速度。数据采集处理单元可以设定、采集相关参数，拉力传感器采用轮辐式结构，精度可达0.05％。The existing commercial safety valve online calibrator is mainly composed of three parts: a mechanical fixture, a hydraulic power unit and a data acquisition and processing unit. Among them, the mechanical fixture mainly clamps and positions the safety valve, and provides an external force actuator for the hydraulic system. According to the different safety valve specifications, there are various jigs of different sizes. The mechanical fixture adopts a combined structure, which is easy to disassemble, safe and reliable. The hydraulic power unit mainly consists of manual/automatic pumps that provide adjustable hydraulic output and flow to control the applied lift force and lift speed. The data acquisition and processing unit can set and collect relevant parameters. The tensile force sensor adopts a spoke structure, and the accuracy can reach 0.05%.

现有技术这种安全阀在线检测是利用压力容器内自身的介质进行在线检测，不能对易燃易爆有毒有害气体及流体中含有颗粒或杂质的介质进行在线检测，不能在线检测安全阀的密封试验压力值。In the prior art, this kind of on-line detection of the safety valve uses the medium in the pressure vessel to perform on-line detection, and cannot perform on-line detection on flammable, explosive, toxic and harmful gases and the medium containing particles or impurities in the fluid, and cannot detect the sealing of the safety valve on-line. Test pressure value.

发明内容SUMMARY OF THE INVENTION

本发明所要解决的技术问题是针对现有技术中存在的上述不足，提供一种安全阀在线检测系统及检测方法，实现了安全阀在线检测密封试验压力，使用外加氮气作为试验介质，能对易燃易爆有毒有害气体及流体中含有颗粒或杂质的介质进行检测，用于在线检测安全阀的密封试验压力值。The technical problem to be solved by the present invention is to aim at the above-mentioned deficiencies in the prior art, and to provide an online detection system and detection method for a safety valve, which realizes the online detection of the sealing test pressure of the safety valve. Inflammable, explosive, toxic and harmful gases and media containing particles or impurities in the fluid are detected, and it is used to detect the sealing test pressure value of the safety valve online.

解决本发明技术问题所采用的技术方案是提供一种安全阀在线检测系统，包括：The technical solution adopted to solve the technical problem of the present invention is to provide an online detection system for safety valves, including:

介质储存单元，用于储存安全阀检测用介质；The medium storage unit is used to store the medium for safety valve detection;

输送管路，与介质存储单元连接，输送管路用于输送安全阀检测用介质；The conveying pipeline is connected with the medium storage unit, and the conveying pipeline is used for conveying the medium for safety valve detection;

空腔，通过输送管路与介质储存单元连接，空腔用于缓存安全阀检测用介质，空腔包括：空腔本体、设置于空腔本体上的空腔入口、空腔第一出口、空腔第二出口，空腔入口通过输送管路与介质储存单元连接，空腔第一出口用于与待检测的安全阀进口连接；The cavity is connected with the medium storage unit through the conveying pipeline, and the cavity is used for buffering the medium used for the detection of the safety valve. The cavity includes: a cavity body, a cavity inlet set on the cavity body, a cavity first outlet, a cavity The second outlet of the cavity, the inlet of the cavity is connected with the medium storage unit through the conveying pipeline, and the first outlet of the cavity is used for connecting with the inlet of the safety valve to be detected;

第一阀门，设置于介质储存单元与空腔之间的输送管路上，用于向空腔内补气；The first valve is arranged on the conveying pipeline between the medium storage unit and the cavity, and is used for supplying air to the cavity;

第二阀门，设置于空腔第二出口的连接管路上，用于对空腔进行泄压；The second valve is arranged on the connecting pipeline of the second outlet of the cavity, and is used to relieve the pressure of the cavity;

第一压力检测单元，设置于第一阀门与空腔之间的输送管路上，且靠近于空腔入口，第一压力检测单元用于检测空腔内的介质压力，并发送给控制单元；The first pressure detection unit is arranged on the conveying pipeline between the first valve and the cavity, and is close to the cavity inlet, and the first pressure detection unit is used to detect the medium pressure in the cavity and send it to the control unit;

控制单元，用于通过调节第一阀门、第二阀门来控制空腔内的压力为预设压力，对安全阀进行在线启跳压力、密封试验的检测。其中，安全阀为弹簧式安全阀。The control unit is used to control the pressure in the cavity to be a preset pressure by adjusting the first valve and the second valve, and perform online tripping pressure and sealing test detection on the safety valve. Among them, the safety valve is a spring-type safety valve.

优选的是，介质储存单元包括：储存罐、与储存罐连接的减压阀，储存罐与空腔连接，储存罐用于储存安全阀检测用介质，减压阀设置于储存罐与空腔之间的输送管路上，且位于第一阀门上游，减压阀用于对储存罐减压的气体减压便于安全阀检测时所需的压力。Preferably, the medium storage unit includes: a storage tank and a pressure reducing valve connected to the storage tank, the storage tank is connected to the cavity, the storage tank is used to store the medium for detection of the safety valve, and the pressure reducing valve is arranged between the storage tank and the cavity On the conveying pipeline between and located upstream of the first valve, the pressure reducing valve is used to reduce the pressure of the gas decompressed in the storage tank, which is convenient for the safety valve to detect the required pressure.

优选的是，第一压力检测单元包括：第一压力检测模块、报警模块、第一显示模块，第一压力检测模块用于检测空腔内的压力并发送给控制单元，第一显示模块用于显示控制单元接收到的压力值，当空腔内的压力超过报警压力值，控制单元控制报警模块发出报警指令并自动调节第二阀门开度泄压。Preferably, the first pressure detection unit includes: a first pressure detection module, an alarm module, and a first display module. The first pressure detection module is used to detect the pressure in the cavity and send it to the control unit, and the first display module is used to detect the pressure in the cavity and send it to the control unit. Display the pressure value received by the control unit. When the pressure in the cavity exceeds the alarm pressure value, the control unit controls the alarm module to issue an alarm command and automatically adjusts the opening of the second valve to release pressure.

优选的是，所述的安全阀在线检测系统，还包括：第二压力检测单元，设置于第一阀门与空腔之间的输送管路上，第二压力检测单元用于检测并显示输入管路内的压力。Preferably, the safety valve online detection system further comprises: a second pressure detection unit, which is arranged on the conveying pipeline between the first valve and the cavity, and the second pressure detection unit is used to detect and display the input pipeline pressure within.

优选的是，第一快速接头，设置于第一阀门与介质储存单元之间的输入管路上；Preferably, the first quick connector is arranged on the input pipeline between the first valve and the medium storage unit;

第二快速接头，设置于第二压力检测单元与空腔之间的输入管路上。The second quick connector is arranged on the input pipeline between the second pressure detection unit and the cavity.

优选的是，所述的安全阀在线检测系统，还包括：安装支架，用于支撑安装空腔，安装支架包括：安装平台、设置于安装平台上的三爪卡，空腔还包括设置于空腔本体下的底座，三爪卡与底座连接。Preferably, the safety valve on-line detection system further includes: an installation bracket for supporting the installation cavity, the installation bracket includes: an installation platform and a three-claw clamp arranged on the installation platform, and the cavity further includes an installation platform arranged in the empty cavity. The base under the cavity body is connected with the base by the three-claw card.

本发明还提供一种使用上述的安全阀在线检测系统的检测方法，包括以下步骤：The present invention also provides a detection method using the above-mentioned safety valve online detection system, comprising the following steps:

将待检测安全阀的安全阀进口与空腔第一出口连接，通过介质储存单元提供检测用介质；Connect the safety valve inlet of the safety valve to be tested with the first outlet of the cavity, and provide the testing medium through the medium storage unit;

通过控制单元调节第一阀门、第二阀门来控制空腔内的压力为预设压力，对安全阀进行在线启跳回落压力的密封试验检测，若在线启跳回落压力的密封试验检测合格，再对安全阀进行在线回座压力的密封试验检测。The first valve and the second valve are adjusted by the control unit to control the pressure in the cavity to be the preset pressure, and the safety valve is subjected to the online jump-back pressure seal test. If the online jump-back pressure seal test is qualified, then Carry out on-line reseating pressure sealing test detection for safety valve.

优选的是，空腔的安装位置为待检测的安全阀与根部阀之间装有带夹持器的爆破片或法兰短节的位置。Preferably, the installation position of the cavity is a position where a rupture disc with a holder or a flange pup joint is installed between the safety valve to be tested and the root valve.

优选的是，所述步骤对安全阀进行在线启跳回落压力的密封试验检测的具体方法为：Preferably, the specific method for performing the sealing test detection of the online jump-back pressure on the safety valve in the step is:

打开第一阀门、关闭第二阀门，通过介质储存单元提供检测用介质，当待检测安全阀启跳回落时，若第一压力检测单元检测到空腔内的压力为第一预设压力，则控制器控制关闭第一阀门，检测由介质储存单元到安全阀之间的管路以及零部件、由空腔到第二阀门出口的连接管路之间的管路以及零部件的密封点的密封性，若第一预设压力在第一预设时间内不变，则密封试验合格，否则密封试验不合格。Open the first valve and close the second valve, and provide the detection medium through the medium storage unit. When the safety valve to be detected jumps and falls, if the first pressure detection unit detects that the pressure in the cavity is the first preset pressure, then The controller controls the closing of the first valve, and detects the sealing of the pipeline from the medium storage unit to the safety valve and the parts, the pipeline from the cavity to the outlet of the second valve, and the sealing point of the parts. If the first preset pressure does not change within the first preset time, the sealing test is qualified, otherwise the sealing test is unqualified.

优选的是，所述步骤对安全阀进行在线启跳回落压力的密封试验检测中，若第一压力检测单元检测到空腔内的压力大于第一预设压力，则通过控制单元打开第二阀门进行泄压，直至第一压力检测单元检测到空腔内的压力为第一预设压力，再自动关闭第二阀门；Preferably, in the step of performing an on-line jump-back pressure sealing test detection on the safety valve, if the first pressure detection unit detects that the pressure in the cavity is greater than the first preset pressure, the control unit opens the second valve performing pressure relief until the first pressure detection unit detects that the pressure in the cavity is the first preset pressure, and then automatically closes the second valve;

若第一压力检测单元检测到空腔内的压力小于第一预设压力，则通过控制单元打开第一阀门进行补气，直至第一压力检测单元检测到空腔内的压力为第一预设压力，再关闭第一阀门。If the first pressure detection unit detects that the pressure in the cavity is lower than the first preset pressure, the control unit opens the first valve to perform air supplementation until the first pressure detection unit detects that the pressure in the cavity is the first preset pressure pressure, and then close the first valve.

优选的是，第一预设压力为0.9倍启跳压力*(1+±0.10％)KPa，第一预设时间为3～10分钟。Preferably, the first preset pressure is 0.9 times the starting pressure*(1+±0.10%)KPa, and the first preset time is 3-10 minutes.

优选的是，所述步骤对安全阀进行在线回座压力的密封试验检测的具体方法为：Preferably, the specific method of performing the online reseating pressure sealing test detection on the safety valve in the step is:

打开第一阀门、关闭第二阀门，通过介质储存单元提供检测用介质，当待检测安全阀回座时，若第一压力检测单元检测到空腔内的压力为第二预设压力，则控制器控制关闭第一阀门，检测由介质储存单元到安全阀之间的管路以及零部件、由空腔到第二阀门出口的连接管路之间的管路以及零部件的密封点的密封性，若第二预设压力在第二预设时间内不变，则密封试验合格，否则密封试验不合格。Open the first valve and close the second valve, and provide the detection medium through the medium storage unit. When the safety valve to be detected is seated, if the first pressure detection unit detects that the pressure in the cavity is the second preset pressure, the control The controller controls and closes the first valve, and detects the tightness of the pipeline from the medium storage unit to the safety valve and the parts, the pipeline from the cavity to the second valve outlet, and the sealing point of the parts. , if the second preset pressure does not change within the second preset time, the sealing test is qualified, otherwise the sealing test is unqualified.

优选的是，第二预设压力为0.9倍启跳压力*(1+±0.10％)KPa，第二预设时间为3～10分钟。Preferably, the second preset pressure is 0.9 times the starting pressure*(1+±0.10%)KPa, and the second preset time is 3-10 minutes.

优选的是，在对安全阀进行在线回座压力时的密封试验检测，若检测结果不合格，所述方法还包括以下步骤：Preferably, the method further includes the following steps if the test result is unqualified when the safety valve is tested for the sealing test during the on-line reseating pressure:

若安全阀的阀芯与阀座之间的密封面有颗粒或杂质，则通过氮气对安全阀的阀芯与阀座之间的密封面吹扫至少两次，再用同样的方法对安全阀进行在线回座压力的密封试验检测，若还是密封试验不合格，则拆卸安全阀，修复或更换相应的零件后，重新进行安全阀在线检测系统的密封试验检测。If there are particles or impurities on the sealing surface between the valve core and the valve seat of the safety valve, purge the sealing surface between the valve core and the valve seat of the safety valve at least twice with nitrogen, and then use the same method to clean the safety valve. Carry out the sealing test detection of the online reseating pressure. If the sealing test is still unqualified, disassemble the safety valve, repair or replace the corresponding parts, and then perform the sealing test detection of the online safety valve detection system again.

本发明中的安全阀在线检测系统及检测方法的有益效果：The beneficial effects of the safety valve on-line detection system and detection method in the present invention:

对申请延期一年以上长周期运行的安全阀进行不停车在线进行启跳压力和密封压力的检测，满足相关法律法规要求，符合相关主管部门对在用安全阀每年至少校验一次的要求。For safety valves that apply for an extension of more than one year for long-term operation, the testing of the starting pressure and sealing pressure shall be carried out on-line without stopping, which meets the requirements of relevant laws and regulations, and meets the requirements of the relevant competent authorities for the safety valves in use to be calibrated at least once a year.

当安全阀在常温、常压下进行离线冷态校验时，利用安全阀在线检测装置可以解决如下现场实际问题：When the safety valve is subjected to offline cold state verification under normal temperature and pressure, the use of the safety valve online detection device can solve the following practical problems:

①为了节省大检修时间，大检修开始停车前筛选出不需要检修的安全阀进行在线检测，尤其是大口径、安装位置高的安全阀计划安排在非大检修时进行在线检测，既为大修节省时间，又减少了拆卸、吊装、安全的工期和费用(以目前某晶体硅3.6万吨/年项目精馏单元口径大于80毫米，安装位置特殊的安全阀为例，通过测算，每年节省吊车等辅助费用至少30万元。)；①In order to save the time of overhaul, the safety valves that do not need to be overhauled are screened out for online inspection before the overhaul starts, especially the safety valves with large diameter and high installation position are scheduled to be inspected online during non-overhaul, which not only saves money for overhaul It also reduces the construction period and cost of dismantling, hoisting, and safety (taking the current 36,000-ton/year crystalline silicon project with a rectification unit whose diameter is greater than 80 mm and a safety valve with a special installation position as an example, through calculation, cranes can be saved every year, etc. Ancillary costs of at least 300,000 yuan.);

②若在离线校验台整定后的安全阀经运输、就位安装等环节的影响安全阀的启跳压力往往发生变化，对此，利用本发明设计的检测系统和方法在投料开车前对此安全阀进行再次启跳压力和密封压力的检测；②If the safety valve after being set on the off-line calibration bench is affected by the transportation, in-situ installation, etc., the tripping pressure of the safety valve tends to change. For this, the detection system and method designed by the present invention are used to detect this before the material is put into operation. The safety valve is tested for the re-triggering pressure and sealing pressure;

③对由于安全阀的弹簧刚度太大引起安全阀出现阀瓣频跳或颤振，在现场改用刚度适当的弹簧后，对安全阀进行启跳和密封的在线检测；或安全阀的调节圈调整不当，使回座压力过高引起安全阀出现阀瓣频跳或振动，通过重新调整调节圈位置后，再次在线进行启跳和密封检测。③ For the valve flap frequency jumping or fluttering of the safety valve caused by the high spring stiffness of the safety valve, after switching to a spring with appropriate stiffness on site, conduct on-line detection of the opening and sealing of the safety valve; or the adjustment ring of the safety valve Improper adjustment will cause the valve disc to jump or vibrate due to the high re-seating pressure. After re-adjusting the position of the adjusting ring, the start-up and seal detection are performed online again.

本发明中的安全阀在线检测系统及检测方法检测精确度高，误差因素减至最小。通过选用精度等级较高的仪器、合理标定检测仪，等办法，提高检测准确度。The on-line detection system and detection method of the safety valve in the present invention have high detection accuracy and minimize error factors. The detection accuracy can be improved by selecting instruments with higher accuracy grades, rationally calibrating the detectors, etc.

附图说明Description of drawings

图1为本发明实施例2中的安全阀在线检测系统进行在线检测时的结构示意图；1 is a schematic structural diagram of the on-line detection system of the safety valve inEmbodiment 2 of the present invention during on-line detection;

图2为本发明实施例2中的空腔的结构示意图；2 is a schematic structural diagram of a cavity inEmbodiment 2 of the present invention;

图3为本发明实施例2中的安全阀在线检测系统投用前密封试验时的结构示意图；3 is a schematic structural diagram of the safety valve on-line detection system inEmbodiment 2 of the present invention during a sealing test before being put into use;

图4为本发明实施例2中的安全阀在线检测系统模拟检测时的结构示意图；4 is a schematic structural diagram of the safety valve on-line detection system inEmbodiment 2 of the present invention when simulating detection;

图5为本发明实施例2中的安全阀在线检测系统的安装平台的主视图；Fig. 5 is the front view of the installation platform of the safety valve on-line detection system inEmbodiment 2 of the present invention;

图6为本发明实施例2中的安全阀在线检测系统的安装平台的俯视图；Fig. 6 is the top view of the installation platform of the safety valve on-line detection system inEmbodiment 2 of the present invention;

图7为本发明实施例2中的安全阀在线检测系统的三爪卡的单爪主视图；7 is a single-claw front view of a three-claw clamp of the safety valve on-line detection system inEmbodiment 2 of the present invention;

图8为本发明实施例2中的安全阀在线检测系统的三爪卡的单爪俯视图；Fig. 8 is the single-claw top view of the three-claw clamp of the safety valve on-line detection system inEmbodiment 2 of the present invention;

图9为本发明实施例2中的安全阀在线检测系统的底座的结构示意图。FIG. 9 is a schematic structural diagram of the base of the safety valve on-line detection system inEmbodiment 2 of the present invention.

图中：1-高压氮气瓶；2-减压阀；3-第一快速接头；4-第一阀门；5-第一球阀；6-压力传感器；7-第二快速接头；8-安全阀；9-空腔；10-第三球阀；11-第二阀门；12-第二球阀；13-安全阀泄放缓冲罐；14-第五球阀；15-压力表；16-第四球阀；17-安全阀；18-压力容器；19-高压软管；20-钢管；21-垫片；22-双头螺栓；23-外丝接头；24-内丝接头；25-弯头；26-压力表接头；27-三通；28-压力开关；29-三通；30-盲板；31-盲法兰；32-底座；33-三爪卡；34-双头螺栓；35-安装平台；36-平板；37-支腿；38-脚板；39-盲法兰；40-钢管；41-圆柱体。In the figure: 1- high pressure nitrogen cylinder; 2- pressure reducing valve; 3- first quick connector; 4- first valve; 5- first ball valve; 6- pressure sensor; 7- second quick connector; 8- safety valve ;9-cavity;10-third ball valve;11-second valve;12-second ball valve;13-safety valve discharge buffer tank;14-fifth ball valve;15-pressure gauge;16-fourth ball valve; 17-safety valve; 18-pressure vessel; 19-high pressure hose; 20-steel pipe; 21-gasket; 22-stud bolt; 23-outer wire joint; 24-inner wire joint; 25-elbow; Pressure gauge connector; 27-Tee; 28-Pressure switch; 29-Tee; 30-Blind plate; 31-Blind flange; 32-Base; ; 36-flat plate; 37-outrigger; 38-foot plate; 39-blind flange; 40-steel pipe; 41-cylinder.

具体实施方式Detailed ways

为使本领域技术人员更好地理解本发明的技术方案，下面结合附图和具体实施方式对本发明作进一步详细描述。In order to make those skilled in the art better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

下面详细描述本专利的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本专利，而不能理解为对本专利的限制。Embodiments of the present patent are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present patent, but should not be construed as a limitation on the present patent.

实施例1Example 1

本实施例提供一种安全阀在线检测系统，包括：The present embodiment provides an online detection system for a safety valve, including:

控制单元，用于通过调节第一阀门、第二阀门来控制空腔内的压力为预设压力，对安全阀进行在线启跳压力、密封试验的检测。The control unit is used to control the pressure in the cavity to be a preset pressure by adjusting the first valve and the second valve, and perform online tripping pressure and sealing test detection on the safety valve.

本实施例还提供一种使用上述的安全阀在线检测系统的检测方法，包括以下步骤：This embodiment also provides a detection method using the above-mentioned safety valve online detection system, comprising the following steps:

本实施例中的安全阀在线检测系统及检测方法的有益效果：The beneficial effects of the safety valve online detection system and detection method in the present embodiment:

实施例2Example 2

如图1～9所示，本实施例提供一种安全阀在线检测系统，包括：As shown in FIGS. 1 to 9 , this embodiment provides an online detection system for a safety valve, including:

介质储存单元，用于储存安全阀8检测用介质；The medium storage unit is used to store the medium used for the detection of the safety valve 8;

输送管路，与介质存储单元连接，输送管路用于输送安全阀8检测用介质；The conveying pipeline is connected with the medium storage unit, and the conveying pipeline is used for conveying the medium used for the detection of the safety valve 8;

空腔9，通过输送管路与介质储存单元连接，空腔9用于缓存安全阀8检测用介质，空腔9包括：空腔本体、设置于空腔本体上的空腔入口、空腔第一出口、空腔第二出口，空腔入口通过输送管路与介质储存单元连接，空腔第一出口用于与待检测的安全阀进口连接；The cavity 9 is connected to the medium storage unit through the conveying pipeline. The cavity 9 is used for buffering the medium used for the detection of the safety valve 8. The cavity 9 includes: a cavity body, a cavity inlet set on the cavity body, a cavity first an outlet and a second outlet of the cavity, the inlet of the cavity is connected with the medium storage unit through the conveying pipeline, and the first outlet of the cavity is used to connect with the inlet of the safety valve to be detected;

第一阀门4，设置于介质储存单元与空腔9之间的输送管路上，用于向空腔9内补气；具体的，本实施例中第一阀门4为电动调节阀，用于补气。The first valve 4 is arranged on the conveying pipeline between the medium storage unit and the cavity 9, and is used to supply air to the cavity 9; gas.

第二阀门11，设置于空腔第二出口的连接管路上，用于对空腔9进行泄压；具体的，本实施例中第二阀门11为电动调节阀，用于泄压。Thesecond valve 11 is arranged on the connecting pipeline of the second outlet of the cavity, and is used to relieve the pressure of the cavity 9; specifically, thesecond valve 11 in this embodiment is an electric regulating valve, which is used for pressure relief.

第一压力检测单元，设置于第一阀门4与空腔9之间的输送管路上，且靠近于空腔入口，第一压力检测单元用于检测空腔9内的介质压力，并发送给控制单元；The first pressure detection unit is arranged on the conveying pipeline between the first valve 4 and the cavity 9, and is close to the cavity inlet. The first pressure detection unit is used to detect the medium pressure in the cavity 9 and send it to the control unit;

控制单元，用于通过调节第一阀门4、第二阀门11来控制空腔9内的压力为预设压力，对安全阀8进行在线启跳压力、密封试验的检测。The control unit is used to control the pressure in the cavity 9 to be a preset pressure by adjusting the first valve 4 and thesecond valve 11 , and perform online tripping pressure and sealing test detection on the safety valve 8 .

具体的，本实施例中的安全阀8为弹簧式安全阀，且为弹簧式直接载荷式安全阀。Specifically, the safety valve 8 in this embodiment is a spring-type safety valve, and is a spring-type direct-load safety valve.

优选的是，介质储存单元包括：储存罐、与储存罐连接的减压阀2，储存罐与空腔9连接，储存罐用于储存安全阀8检测用介质，减压阀2设置于储存罐与空腔9之间的输送管路上，且位于第一阀门4上游，减压阀2用于对储存罐减压的气体减压便于安全阀8检测时所需的压力。具体的，本实施例中的储存罐为高压氮气瓶1，检测用介质为氮气。Preferably, the medium storage unit includes: a storage tank, apressure reducing valve 2 connected to the storage tank, the storage tank is connected to the cavity 9, the storage tank is used to store the medium used for the detection of the safety valve 8, and thepressure reducing valve 2 is arranged in the storage tank On the conveying pipeline between the cavity 9 and the first valve 4 and upstream of the first valve 4 , thepressure reducing valve 2 is used to reduce the pressure of the gas decompressed in the storage tank to facilitate the pressure required by the safety valve 8 to detect. Specifically, the storage tank in this embodiment is a high-pressure nitrogen cylinder 1, and the detection medium is nitrogen.

优选的是，第一压力检测单元包括：第一压力检测模块、报警模块、第一显示模块，第一压力检测模块用于检测空腔9内的压力并发送给控制单元，第一显示模块用于显示控制单元接收到的压力值，当空腔9内的压力超过报警压力值，控制单元控制报警模块发出报警指令并自动调节第二阀门11开度泄压。具体的，本实施例中的第一压力检测单元为压力开关28。Preferably, the first pressure detection unit includes: a first pressure detection module, an alarm module, and a first display module. The first pressure detection module is used to detect the pressure in the cavity 9 and send it to the control unit. The first display module uses In order to display the pressure value received by the control unit, when the pressure in the cavity 9 exceeds the alarm pressure value, the control unit controls the alarm module to issue an alarm command and automatically adjust the opening of thesecond valve 11 to release pressure. Specifically, the first pressure detection unit in this embodiment is thepressure switch 28 .

优选的是，所述的安全阀在线检测系统，还包括：第二压力检测单元，设置于第一阀门4与空腔9之间的输送管路上，第二压力检测单元用于检测并显示输入管路内的压力。具体的，本实施例中的第二压力检测单元位于第一压力检测单元的上游。具体的，本实施例中的第二压力检测单元包括压力传感器6(带压力开关)。Preferably, the safety valve online detection system further includes: a second pressure detection unit, which is arranged on the conveying pipeline between the first valve 4 and the cavity 9, and the second pressure detection unit is used to detect and display the input pressure in the pipeline. Specifically, the second pressure detection unit in this embodiment is located upstream of the first pressure detection unit. Specifically, the second pressure detection unit in this embodiment includes a pressure sensor 6 (with a pressure switch).

优选的是，第一快速接头3，设置于第一阀门4与介质储存单元之间的输入管路上；Preferably, the first quick connector 3 is arranged on the input pipeline between the first valve 4 and the medium storage unit;

第二快速接头7，设置于第二压力检测单元与空腔9之间的输入管路上。The second quick connector 7 is arranged on the input pipeline between the second pressure detection unit and the cavity 9 .

优选的是，所述的安全阀在线检测系统，还包括：安装支架，用于支撑安装空腔9，安装支架包括：安装平台35、设置于安装平台35上的三爪卡33，空腔9还包括设置于空腔本体下的底座32，三爪卡33与底座32连接。Preferably, the safety valve on-line detection system further includes: an installation bracket for supporting the installation cavity 9, the installation bracket includes: aninstallation platform 35, a three-claw clamp 33 arranged on theinstallation platform 35, the cavity 9 It also includes a base 32 disposed under the cavity body, and the three-claw clip 33 is connected to the base 32 .

具体的，本实施例中高压氮气瓶1、减压阀2、高压软管19、第一快速接头3、钢管20、第一阀门4、第二压力检测单元、第二快速接头7、第一压力检测单元、空腔9依次连接。第二压力检测单元通过三通27分别与第一阀门4、第二快速接头7连接，第二压力检测单元与三通27之间连接设置有第一球阀5。Specifically, in this embodiment, the high-pressure nitrogen cylinder 1, thepressure reducing valve 2, the high-pressure hose 19, the first quick connector 3, thesteel pipe 20, the first valve 4, the second pressure detection unit, the second quick connector 7, the first quick connector The pressure detection unit and the cavity 9 are connected in sequence. The second pressure detection unit is respectively connected with the first valve 4 and the second quick connector 7 through the tee 27 , and a first ball valve 5 is connected between the second pressure detection unit and the tee 27 .

空腔第一出口与待检安全阀8进口相通，待检安全阀8通过管道与安全阀泄放缓冲罐13通过管道连接，待检安全阀8与安全阀泄放缓冲罐13之间的管道上设置有第二球阀12，空腔第二出口与第二阀门11连接。The first outlet of the cavity is communicated with the inlet of the safety valve 8 to be inspected, the safety valve 8 to be inspected is connected to the safety valvedischarge buffer tank 13 through a pipeline, and the pipeline between the safety valve 8 to be inspected and the safety valve discharge buffer tank 13 A second ball valve 12 is arranged on the upper part, and the second outlet of the cavity is connected with thesecond valve 11 .

空腔9还包括设置于空腔本体上的空腔第三出口，空腔第三出口通过管道与压力容器18连接，空腔9与压力容器18之间的管道上设置有第三球阀10。压力容器18通过管道与正常使用的安全阀17连接，压力容器18与正常使用的安全阀17之间的管道上设置有第四球阀16。压力容器18通过管道与压力表15连接，压力容器18与压力表15之间的管道上设置有第五球阀14。The cavity 9 also includes a cavity third outlet disposed on the cavity body, the cavity third outlet is connected to thepressure vessel 18 through a pipeline, and athird ball valve 10 is provided on the pipeline between the cavity 9 and thepressure vessel 18 . Thepressure vessel 18 is connected to the normally usedsafety valve 17 through a pipeline, and afourth ball valve 16 is provided on the pipeline between thepressure vessel 18 and the normally usedsafety valve 17 . Thepressure vessel 18 is connected to thepressure gauge 15 through a pipeline, and a fifth ball valve 14 is provided on the pipeline between thepressure vessel 18 and thepressure gauge 15 .

具体的，本实施例中安全阀在线检测系统中高压氮气瓶1(带专用瓶阀的)提供的检测介质氮气通过减压阀2、高压软管19、第一快速接头3、钢管20、第一阀门4、第二快速接头7进入检测系统中空腔9，空腔9与待检安全阀8进口相通，并利用第二阀门11，对安全阀8进行启跳压力和密封试验压力进行检测，与此同时，氮气通过第一球阀5进入第二压力检测单元(带压力开关)，待检安全阀8进行检测时，第三球阀10处于关闭状态，第二球阀12处于全开状态(而压力容器18上第四球阀16处于全开状态，安全阀17投入使用状态，第五球阀14处于全开状态与压力表15相连，测量并显示该在役压力容器18运行的压力)。第一快速接头3与压力传感器6及第一快速接头3与第二快速接头11之间为钢管20连接。Specifically, the detection medium nitrogen gas provided by the high-pressure nitrogen cylinder 1 (with a special cylinder valve) in the safety valve online detection system in this embodiment passes through thepressure reducing valve 2, the high-pressure hose 19, the first quick connector 3, thesteel pipe 20, the first A valve 4 and a second quick connector 7 enter a cavity 9 in the detection system, and the cavity 9 communicates with the inlet of the safety valve 8 to be inspected, and thesecond valve 11 is used to detect the tripping pressure and the sealing test pressure of the safety valve 8, At the same time, nitrogen gas enters the second pressure detection unit (with a pressure switch) through the first ball valve 5. When the safety valve 8 to be tested is detected, thethird ball valve 10 is in a closed state, and the second ball valve 12 is in a fully open state (while the pressure Thefourth ball valve 16 on thecontainer 18 is in a fully open state, thesafety valve 17 is put into use, and the fifth ball valve 14 is in a fully open state and is connected to thepressure gauge 15 to measure and display the operating pressure of the in-service pressure container 18). Asteel pipe 20 is connected between the first quick connector 3 and the pressure sensor 6 and between the first quick connector 3 and the secondquick connector 11 .

本实施例中的安全阀在线检测系统的组成、构造：The composition and structure of the safety valve online detection system in this embodiment:

(1)储存罐高压氮气瓶1的选用。如图1所示，高压氮气瓶1(带专用瓶阀的)选40L容积，为检测系统提供高压氮气。租用经过国家有关授权的专业机构进行检验合格的，并在使用有效期内的专用无缝钢瓶；(1) Selection of high pressure nitrogen cylinder 1 for storage tank. As shown in Figure 1, the high-pressure nitrogen bottle 1 (with a special bottle valve) has a volume of 40L to provide high-pressure nitrogen for the detection system. Rent special seamless steel cylinders that have been inspected by professional institutions authorized by the state and are within the validity period of use;

(2)减压阀2的选用。如图1所示，减压阀2为氮气等气体的标配减压阀，选择FARFLOW 813减压阀的本体是由黄铜<HPb59-1>制成。FARFLOW 818型减压阀进气接头内螺纹与瓶阀外螺纹尺寸为G5/8"，接头的内径尺寸为5.5mm,出气接头与高压软管19外螺纹相连，螺纹规格为G5/8"，内径尺寸为5.5mm，其最大流量为80m³/h。减压阀2本体上还装有高压氮气表和低压氮气表，分别指示高压气室(即氮气瓶内)和低压气室内的压力(即工作压力)。高压氮气表的量程为0～25MPa。低压氮气表的量程为0～4MPa。(2) Selection ofpressure reducing valve 2. As shown in Figure 1, thepressure reducing valve 2 is a standard pressure reducing valve for gases such as nitrogen, and the body of the FARFLOW 813 pressure reducing valve is made of brass <HPb59-1>. The inner thread of the FARFLOW 818 pressure reducing valve is G5/8" and the outer thread of the bottle valve is G5/8". The inner diameter of the joint is 5.5mm. The inner diameter is 5.5mm, and its maximum flow rate is 80m³ /h. The body of thepressure reducing valve 2 is also equipped with a high-pressure nitrogen meter and a low-pressure nitrogen meter, which respectively indicate the pressure in the high-pressure gas chamber (that is, in the nitrogen cylinder) and the pressure in the low-pressure gas chamber (that is, the working pressure). The range of the high pressure nitrogen meter is 0～25MPa. The range of the low pressure nitrogen meter is 0～4MPa.

(3)高压软管19的选用。如图1所示，与减压阀2、第一快速接头3之间连接采用高压软管19，根据待检安全阀8的整定压力大小，本实例选用外径￠10mm高压钢丝软管；其最大长度根据待检安全阀8安装最高位置确定，本实例选用40米长；本实例购买高压软管19一端外螺纹接头与减压阀2内螺纹尺寸为G3/8"匹配，另一端外螺纹与第一快速接头3一端的内螺纹尺寸为G3/8"相匹配连接。(3) Selection ofhigh pressure hose 19. As shown in Figure 1, a high-pressure hose 19 is used to connect with thepressure reducing valve 2 and the first quick connector 3. According to the set pressure of the safety valve 8 to be checked, this example selects a high-pressure steel wire hose with an outer diameter of ￠10mm; The maximum length is determined according to the highest installation position of the safety valve 8 to be inspected. In this example, the length of 40 meters is selected. In this example, the male threaded joint of one end of the high-pressure hose 19 is purchased to match the internal thread size of thepressure reducing valve 2, and the external thread of the other end is G3/8". Match with the internal thread size of one end of the first quick connector 3 is G3/8".

(4)钢管20、三通27、压力表接头26、弯头25、第一阀门4之间的连接方式。如图1所示中，在第一快速接头3另一端外螺纹G3/8"与第一阀门4的一端内螺纹G3/8"相适配，内径尺寸为6.0mm。第一阀门4的另一端内螺纹G3/8"与外螺纹相匹配后与钢管20焊接，钢管20与三通27一端焊接，三通27上端与第一球阀5焊接，三通的另一端与第二快速接头7的一端焊接，第二快速接头7另一端与空腔9之间用钢管20焊接，以及空腔9与第二阀门11之间的管道选用Q345碳钢或不锈钢金属管道￠10*2mm焊接而成；第一球阀5另一上端通过焊接三通29、焊接90度弯头25、钢管20分别与2个压力表接头26焊接后，与2个压力传感器6的外螺纹匹配连接，压力表接头26的螺纹接口为M20*1.5。(4) The connection between thesteel pipe 20 , the tee 27 , the pressure gauge joint 26 , theelbow 25 , and the first valve 4 . As shown in FIG. 1 , the outer thread G3/8" at the other end of the first quick connector 3 is matched with the inner thread G3/8" at one end of the first valve 4, and the inner diameter is 6.0 mm. The other end of the first valve 4 is welded with the inner thread G3/8" after matching the outer thread with thesteel pipe 20, thesteel pipe 20 is welded with one end of the tee 27, the upper end of the tee 27 is welded with the first ball valve 5, and the other end of the tee is welded with the first ball valve 5. One end of the second quick joint 7 is welded, the other end of the second quick joint 7 and the cavity 9 are welded with asteel pipe 20, and the pipe between the cavity 9 and thesecond valve 11 is selected from Q345 carbon steel or stainless steel metal pipe ￠10 *2mm welded; the other upper end of the first ball valve 5 is welded with the two pressure gauge joints 26 by welding thetee 29, the welded 90-degree elbow 25, and thesteel pipe 20, and then matched with the external threads of the two pressure sensors 6. , the threaded interface of thepressure gauge connector 26 is M20*1.5.

(5)第一快速接头3、第二快速接头7的选用。如图1所示，第一快速接头3、第二快速接头7，选用两端开闭式快速接头，它由接头体、单向阀阀芯、外套、钢球、弹簧和密封组成。接头体的内腔有一个单向阀，当两个接头体分离开时，单向阀阀芯在各自的弹簧作用下外伸，并顶压在接头体的锥形孔上，使通路关闭，两边管子内的流体被封闭在管中不能流出；当两个接头体连接时，单向阀阀芯前端的两顶杆相碰，迫使阀芯离开接头体的锥形孔，使两边管子内的流体相通，两个接头体用钢球锁紧，工作时，外套在弹簧作用下把钢球压在接头体的U形槽内，使接头体连接。本实施例中的第一快速接头3、第二快速接头7选用开闭式液压快速接头，其材质为304不锈钢，也适用于氮气为介质的场合。公称压力为350kgf/cm²，介质温度为-20℃～+80℃。规格(英寸)G3/8"，额定压力(psi)2000，相当于20MPa。第一快速接头3另一端外螺纹G3/8"与第一阀门4的一端内螺纹G3/8"，内径尺寸为6.0mm，匹配第一快速接头3。第一快速接头3通过内丝接头24与钢管20连接后与空腔9连接，第二快速接头7通过外丝接头23与钢管20连接后与空腔9连接。(5) Selection of the first quick connector 3 and the second quick connector 7 . As shown in Figure 1, the first quick connector 3 and the second quick connector 7 are quick connectors with opening and closing at both ends, which are composed of a connector body, a check valve core, a jacket, a steel ball, a spring and a seal. There is a one-way valve in the inner cavity of the joint body. When the two joint bodies are separated, the valve core of the one-way valve stretches out under the action of their respective springs and presses on the conical hole of the joint body to close the passage. The fluid in the pipes on both sides is enclosed in the pipes and cannot flow out; when the two joint bodies are connected, the two push rods at the front end of the one-way valve spool collide, forcing the spool to leave the conical hole of the joint body, so that the fluid in the two pipes The fluid is in communication, and the two joint bodies are locked with steel balls. When working, the outer sleeve presses the steel balls into the U-shaped groove of the joint body under the action of the spring, so that the joint bodies are connected. In this embodiment, the first quick joint 3 and the second quick joint 7 are open-closed hydraulic quick joints, which are made of 304 stainless steel, and are also suitable for occasions where nitrogen is the medium. The nominal pressure is 350kgf/cm² and the medium temperature is -20℃～+80℃. Specification (inch) G3/8", rated pressure (psi) 2000, equivalent to 20MPa. The other end of the first quick connector 3 has an external thread of G3/8" and one end of the first valve 4 has an internal thread of G3/8". The inner diameter is 6.0mm, matching the first quick connector 3. The first quick connector 3 is connected with thesteel tube 20 through theinner wire connector 24 and then connected with the cavity 9, and the second quick connector 7 is connected with thesteel tube 20 through theouter wire connector 23 and then connected with the cavity 9 connect.

(6)第一阀门4、第二阀门11的选用(第一球阀5为手动阀，其公称直径、公称压力与第一阀门4一致)。如图1所示，第一阀门4、第二阀门11均为电动调节阀，第一阀门4、第二阀门11都选用内螺纹连接G3/8"，内径尺寸为6.0mm的专用调节阀与管道相连接，不选球阀和蝶阀。由电动执行机构和调节阀连接组合后经过机械连接装配、调试安装构成电动调节阀。工作电源：DC24V,AC220V,AC380V等电压等级。输入控制信号：DC4-20MA或者DC1-5V，反馈控制信号：DC4-20MA(负载电阻碍500欧姆以下)；通过接收工业自动化控制系统的信号(如：4～20mA)来驱动阀门改变阀芯和阀座之间的截面积大小控制管道介质的流量、温度、压力等工艺参数，实现自动化调节功能。新型电动调节阀执行器内含饲服功能，接受统一的4-20mA或1-5V·DC的标准信号，将电流信号转变成相对应的直线位移，自动地控制调节阀开度，达到对管道内流体的压力、流量、温度等工艺参数的连续调节；电动调节阀采用API等国际先进标准。公称通径6mm，公称压力40.0Mpa,工作温度-196℃-800℃的阀门，产品材质选304不锈钢。(6) Selection of the first valve 4 and the second valve 11 (the first ball valve 5 is a manual valve, and its nominal diameter and nominal pressure are consistent with the first valve 4). As shown in Figure 1, the first valve 4 and thesecond valve 11 are both electric control valves, the first valve 4 and thesecond valve 11 are connected with internal thread G3/8", and the special control valve with an inner diameter of 6.0mm is connected to the Pipes are connected, ball valve and butterfly valve are not selected. The electric control valve is composed of electric actuator and regulating valve after mechanical connection, assembly, debugging and installation. Working power supply: DC24V, AC220V, AC380V and other voltage levels. Input control signal: DC4- 20MA or DC1-5V, feedback control signal: DC4-20MA (load resistance below 500 ohms); drive the valve to change the cutoff between the valve core and the valve seat by receiving the signal from the industrial automation control system (such as: 4 ~ 20mA). The size of the area controls the flow, temperature, pressure and other process parameters of the pipeline medium, and realizes automatic adjustment. The signal is converted into the corresponding linear displacement, and the opening of the regulating valve is automatically controlled to achieve continuous adjustment of the pressure, flow, temperature and other process parameters of the fluid in the pipeline; the electric regulating valve adopts international advanced standards such as API. The nominal diameter is 6mm, The valve with a nominal pressure of 40.0Mpa and a working temperature of -196℃-800℃ is made of 304 stainless steel.

(7)第二压力检测单元为压力传感器6，压力传感器6的选用。如图1所示，压力传感器6，压力传感器6包括压力变送器能满足各种工况环境下气体的压力监控。PAW压力变送控制器的量程:-0.1～60MPa(Max)，测量精度：精度等级:0.1、0.2、0.5，本实施例选用精度等级为0.5级，温度影响:±0.07％FS/10℃，稳定性:±0.10％FS/年，重复性误差:±0.10％FS；工作电压:DC24VDC，介质温度:-20℃～85℃；采用进口压力芯体作测量单元，精度高，线性好，抗冲击，耐腐蚀；表体自带LED显示，支持两线制4-20mA信号输出。(7) The second pressure detection unit is the pressure sensor 6, and the selection of the pressure sensor 6. As shown in FIG. 1 , the pressure sensor 6, including the pressure transmitter, can meet the pressure monitoring of gas under various working conditions. Range of PAW pressure transmitter controller: -0.1～60MPa(Max), measurement accuracy: accuracy grade: 0.1, 0.2, 0.5, in this embodiment, the selected accuracy grade is 0.5, temperature effect: ±0.07%FS/10℃, Stability: ±0.10%FS/year, repeatability error: ±0.10%FS; working voltage: DC24VDC, medium temperature: -20℃～85℃; imported pressure core is used as measuring unit, with high precision, good linearity and resistance to Impact, corrosion resistance; the watch body comes with LED display, supports two-wire 4-20mA signal output.

(8)第一压力检测单位为压力开关28，压力开关28的选用。如图1所示，拟采用具有操作简单、智能化程度高、反应快精度高等优点的电子式智能压力控制开关。压力开关28采用高精度、高稳定性能的压力传感器6和变送电路，再经专用CPU模块化信号处理技术，实现对介质压力信号的检测、显示、报警和控制信号输出。压力开关28采用的弹性元件有单圈弹簧管、膜片、膜盒及波纹管等。压力开关28的工作原理：是当系统内压力高于或低于额定的安全压力时，感应器内碟片瞬时发生移动，通过连接导杆推动开关接头接通或断开，当压力降至或升到额定的恢复值时，碟片瞬时复位，开关自动复位，或者简单的说是当被测压力超过额定值时，弹性元件的自由端产生位移，直接或经过比较后推动开关元件，改变开关元件的通断状态，达到控制被测压力的目的。本实施例压力开关28选用常闭式。压力开关28的压力范围内可根据实际需求选定的压力值进行选购买，本次实例选用4.0MPa。(8) The first pressure detection unit is thepressure switch 28, and the selection of thepressure switch 28. As shown in Figure 1, it is proposed to use an electronic intelligent pressure control switch with the advantages of simple operation, high intelligence, fast response and high precision. Thepressure switch 28 adopts a high-precision, high-stability pressure sensor 6 and a transmission circuit, and then uses the special CPU modular signal processing technology to realize the detection, display, alarm and control signal output of the medium pressure signal. The elastic elements used in thepressure switch 28 include a single-coil spring tube, a diaphragm, a diaphragm, a bellows, and the like. The working principle of the pressure switch 28: when the pressure in the system is higher or lower than the rated safety pressure, the disc in the sensor moves instantaneously, and the switch connector is pushed on or off through the connecting guide rod. When it reaches the rated recovery value, the disc resets instantaneously, and the switch resets automatically. The on-off state of the component to achieve the purpose of controlling the measured pressure. In this embodiment, thepressure switch 28 is normally closed. The pressure value of thepressure switch 28 can be selected and purchased according to the actual demand within the pressure range of thepressure switch 28. In this example, 4.0 MPa is selected.

(9)空腔9选用。如图2所示，空腔9，本实例选用304不锈钢材质，空腔9壁厚略大于压力容器18壁的壁厚，空腔9的高度与爆破片的夹持器高度一样(55mm)，空腔9的外径与夹持器外径相同(￠150mm)，空腔9的内径详见图2，在空腔9壁相互成180度方向上钻孔￠5mm,与来自氮气管￠10*2mm相连，另外一个钻孔￠5mm，与第二阀门11进口管￠10*2mm焊接。空腔9的形状尺寸如下图2所示。(9) The cavity 9 is selected. As shown in Figure 2, the cavity 9 is made of 304 stainless steel in this example, the wall thickness of the cavity 9 is slightly larger than the wall thickness of thepressure vessel 18, and the height of the cavity 9 is the same as the height of the holder of the bursting disc (55mm), The outer diameter of the cavity 9 is the same as the outer diameter of the holder (￠150mm). The inner diameter of the cavity 9 is shown in Figure 2. Drill holes ￠5mm in the direction of 180 degrees on the walls of the cavity 9. *2mm is connected, another drilled hole is ￠5mm, and it is welded with the inlet pipe of thesecond valve 11 ￠10*2mm. The shape and size of the cavity 9 are shown in Figure 2 below.

(10)三通27为等径三通：如图1所示，材质与钢管20材质一致，本实例选用304不锈钢，规格：外径￠10*10*10，内孔直径6mm。(10) The tee 27 is an equal diameter tee: as shown in Figure 1, the material is the same as that of thesteel pipe 20. In this example, 304 stainless steel is selected, and the specifications are: outer diameter ￠10*10*10, inner hole diameter 6mm.

(11)弯头25：如图1所示，材质与钢管20材质一致，本实例选用304不锈钢，90度弯头25，规格￠10*2，内孔直径6mm，数量共计2个。(11) Elbow 25: As shown in Figure 1, the material is the same as that of thesteel pipe 20. In this example, 304 stainless steel, 90-degree elbow 25, specification ￠10*2, inner hole diameter of 6mm, and a total of 2 pieces.

(12)压力表接头26：如图1所示，材质与钢管20材质一致，本实例选用304不锈钢，规格M20*1.5，内孔直径6mm，数量共计2个。(12) Pressure gauge joint 26: As shown in Figure 1, the material is the same as that of thesteel pipe 20. In this example, 304 stainless steel is selected, the specification is M20*1.5, the inner hole diameter is 6mm, and the number is 2 in total.

(13)钢管20：如图1所示，本实例选用规格为￠10*2mm，304不锈钢，总长度约1200mm。(13) Steel pipe 20: As shown in Figure 1, in this example, the specification is ￠10*2mm, 304 stainless steel, and the total length is about 1200mm.

(14)垫片21：如图1所示，根据安全阀8整定压力大小和检测所用的介质、温度等因素进行决定垫片21材质，材质可选择聚四氟乙烯、金属缠绕垫复合聚四氟乙烯、金属垫，压力等级比安全阀8压力至少高一级，本实例选金属缠绕垫复合聚四氟乙烯。垫片21设置于空腔9与安全阀8进口连接处，金属垫材料为低碳钢、金属带材料为0Cr18Ni9；公称通径100mm；公称压力4.0MPa(40bar)；垫片21尺寸标准GB/T4622.2－2003；其标记为：缠绕垫D1222－DN100－PN40。(14) Gasket 21: As shown in Figure 1, the material of the gasket 21 is determined according to the setting pressure of the safety valve 8 and the medium and temperature used for testing. The material can be selected from PTFE, metal wound gasket, composite polytetrafluoroethylene The pressure level of vinyl fluoride and metal gasket is at least one level higher than that of safety valve 8. In this example, metal wound gasket is selected to compound PTFE. The gasket 21 is arranged at the connection between the cavity 9 and the inlet of the safety valve 8. The material of the metal gasket is low carbon steel, and the material of the metal strip is 0Cr18Ni9; the nominal diameter is 100mm; the nominal pressure is 4.0MPa (40bar); the size of the gasket 21 is GB/ T4622.2-2003; it is marked as: winding pad D1222-DN100-PN40.

(15)双头螺栓22：如图1所示，材质为Q345或304不锈钢，根据待检安全阀8时，夹持器所用的螺栓规格相同，本实例选用8.8级高强度双头螺栓22，材质为q345，规格为M18*180mm。用一组双头螺栓22，通过安全阀8和第三球阀10之间夹持器的上下法兰把垫片21、空腔9固定在夹持器位置。(15) Stud bolt 22: As shown in Figure 1, the material is Q345 or 304 stainless steel. According to the safety valve 8 to be inspected, the bolts used in the holder are the same. The material is q345 and the specification is M18*180mm. A set ofstud bolts 22 are used to fix the gasket 21 and the cavity 9 in the position of the holder through the upper and lower flanges of the holder between the safety valve 8 and thethird ball valve 10.

(16)盲板30：如图3所示，本实例选用材质为聚四氟乙烯，厚度3mm，检测系统模拟检测投用前密封试验用，盲板30用于密封空腔9。(16) Blind plate 30 : As shown in FIG. 3 , the material selected in this example is polytetrafluoroethylene with a thickness of 3 mm. The detection system simulates detection and is used for sealing test before putting into use. Theblind plate 30 is used to seal the cavity 9 .

(17)盲法兰31：如图3所示，材质为Q345R，本实例选用公称压力4.0MPa，公称直径DN100mm，检测系统投用前密封试验用，盲板30通过盲法兰31与空腔9连接。(17) Blind flange 31: As shown in Figure 3, the material is Q345R. In this example, the nominal pressure is 4.0MPa and the nominal diameter is DN100mm. It is used for the sealing test before the detection system is put into use. Theblind plate 30 passes through the blind flange 31 and the cavity. 9 connections.

(18)底座32：如图4、9所示，检测系统投用前模拟调式或模拟检测用，它包括：盲法兰39、钢管40、圆柱体41。钢管40为圆钢管短节，盲法兰39与钢管40、钢管40与圆柱体41、圆柱体41上下盖板与圆柱壳体之间都采用焊接联接；底座32材质为Q345R，本实例选用盲法兰39公称压力4.0MPa，公称直径DN100mm；圆钢管短节Q345R外径120mm，壁厚10mm，长度150mm；圆柱外径为340mm，上下盖板及壁厚都是20mm厚，材质为Q345R，与模拟平台35表面接触的表面粗糙度为6.3。(18) Base 32: As shown in Figures 4 and 9, the detection system is used for simulating adjustment or simulating detection before it is put into use. It includes:blind flange 39,steel pipe 40, andcylinder 41. Thesteel pipe 40 is a round steel pipe short joint, and theblind flange 39 and thesteel pipe 40, thesteel pipe 40 and thecylinder 41, and the upper and lower cover plates of thecylinder 41 and the cylinder shell are all connected by welding; the base 32 is made of Q345R, and blind is used in this example.Flange 39 has a nominal pressure of 4.0MPa and a nominal diameter of DN100mm; round steel pipe short joint Q345R has an outer diameter of 120mm, a wall thickness of 10mm and a length of 150mm; the outer diameter of the cylinder is 340mm, and the upper and lower cover plates and wall thicknesses are both 20mm thick. The surface roughness of the surface contact of thesimulation platform 35 is 6.3.

(19)三爪卡33：如图7、8所示，本实例数量为三个，材质Q345R，与安装平台35、底座32中的圆柱表面、与双头螺栓34接触表面，其接触表面的表面粗糙度为6.3，安全阀8在线检测前模拟调试用。(19) Three-jaw clamp 33: As shown in Figures 7 and 8, the number of this example is three, the material is Q345R, the contact surface with the mountingplatform 35, the cylindrical surface in the base 32, and the stud bolt 34, the contact surface The surface roughness is 6.3, and the safety valve 8 is used for simulation debugging before online inspection.

(20)双头螺栓34:如图4所示，本实例选用6套M24*130mm，性能等级8.8高强度螺栓，安全阀8在线检测前模拟调试用，三爪卡33通过双头螺栓34与安装平台35连接。(20) Stud bolt 34: As shown in Figure 4, in this example, 6 sets of M24*130mm, performance grade 8.8 high-strength bolts are selected, and the safety valve 8 is used for simulation debugging before online detection. Mountingplatform 35 is attached.

(21)模拟检测平台35：如图4～6所示，它包括平板36、支腿37、脚板38，平板36用于支撑空腔9，支腿37设置于平板36下方，脚板38与支腿37底部连接；本实例平板36选用材质为Q345R，厚度40mm，表面粗糙度为6.3，并在平面上开了三个槽，槽深40mm、槽宽25mm、槽长125mm；支腿37材质为Q345R，100*100mm方钢，长度800mm；脚板38厚度为40mm，200*200mm，用膨胀螺栓M20*110固定在砼地面上或钢板上。(21) Simulation testing platform 35: As shown in Figures 4 to 6, it includes aflat plate 36,outriggers 37, and afoot plate 38, theflat plate 36 is used to support the cavity 9, theoutrigger 37 is arranged below theflat plate 36, and thefoot plate 38 is connected to the support The bottom of theleg 37 is connected; in this example, theplate 36 is made of Q345R, the thickness is 40mm, the surface roughness is 6.3, and three grooves are opened on the plane, the groove depth is 40mm, the groove width is 25mm, and the groove length is 125mm; the material of thelegs 37 is Q345R, 100*100mm square steel, length 800mm;foot plate 38 thickness is 40mm, 200*200mm, fixed on the concrete floor or steel plate with expansion bolts M20*110.

如图3所示，检测操作前准备工作(或检测顺序)As shown in Figure 3, the preparation work (or the detection sequence) before the detection operation

1、本检测系统的各个元件清理干净、吹扫合格后，把各个元件进行组装；1. After the various components of the detection system are cleaned and purging is qualified, the components are assembled;

2、检查检测系统中的第一压力检测单元、第二压力检测单元应当符合要求。第二压力检测单元包括两块规格相同的压力传感器6，其精确度等级不应当低于1.0级，压力传感器6的量程应当为安全阀8校验压力的1.5～3.0倍(压力传感器6必须定期进行检定，检定周期为6个月)；2. Check that the first pressure detection unit and the second pressure detection unit in the inspection system should meet the requirements. The second pressure detection unit includes two pressure sensors 6 with the same specifications, the accuracy level of which should not be lower than 1.0, and the range of the pressure sensor 6 should be 1.5 to 3.0 times the calibration pressure of the safety valve 8 (the pressure sensor 6 must be regularly verification, the verification period is 6 months);

3、第一压力检测单元安装通电后检查各类参数、量程和零点正常后对其进行投用；3. After the first pressure detection unit is installed and powered on, check all kinds of parameters, range and zero point to be normal and put it into use;

4、PLC通电初始化后检查CPU及各模块运行状态是否正常；4. After the PLC is powered on and initialized, check whether the running status of the CPU and each module is normal;

5、手动打开介质储存单元的充气阀，对这套在线检测系统进行密封性检查合格，如图3所示；5. Manually open the inflation valve of the medium storage unit, and check the tightness of the online detection system, as shown in Figure 3;

6、在这套在线检测系统进行检测前，对安全阀8进行离线模拟调试，如图4所示。通过模拟调试检查第一压力检测单元、第二压力检测单元的灵敏度、精确度，提高这套系统的检测精准度。安全阀8启跳压力或整定压力模拟调试步骤：(1)检查检测系统各零部件安装完成，密封试验合格后，且处于正常状态。(2)在控制单元(PLC)上位机界面设定安全阀8校验启跳压力值P1(不同规格安全阀8启跳压力值不同，需根据实际安全阀8设定启跳压力值)，编译安全阀8启跳声光指示灯控制逻辑是否正确，将第一阀门4和第二阀门11控制模式设定为自动。(3)打开介质储存单元开始充气，直到第一压力检测单元实测压力值P3和第二压力检测单元实测压力值P4的压力信号在启跳压力设定值P1误差范围内，即P1(1±K％)范围内，若启跳指示灯不亮，则需检查控制逻辑、接线回路、安全阀8各零部件动作是否故障，若存在故障，处理正常后重新按以上步骤模拟调试。若启跳指示灯亮，则模拟调试正常，填写相关调试记录，手动关闭第一阀门4，打开第二阀门11排除多余气体，将系统恢复至试验前状态。便可到现场开始启跳试验(注：K％＝±0.10％，为远传压力表15检测精度)。6. Before the on-line testing system is tested, the off-line simulation debugging of the safety valve 8 is carried out, as shown in Figure 4. The sensitivity and accuracy of the first pressure detection unit and the second pressure detection unit are checked through simulation debugging to improve the detection accuracy of this system. Steps for simulating the start-up pressure or set pressure of safety valve 8: (1) Check that the installation of each component of the detection system is completed, the sealing test is qualified, and it is in a normal state. (2) On the control unit (PLC) host computer interface, set the safety valve 8 to verify the tripping pressure value P1 (the tripping pressure value of the safety valve 8 of different specifications is different, and the tripping pressure value needs to be set according to the actual safety valve 8), Compile whether the control logic of the sound and light indicator light for safety valve 8 is correct, and set the control mode of the first valve 4 and thesecond valve 11 to automatic. (3) Open the medium storage unit and start inflating until the pressure signals of the first pressure detection unit measured pressure value P3 and the second pressure detection unit measured pressure value P4 are within the error range of the trigger pressure setting value P1, that is, P1 (1± Within the range of K%), if the start indicator light is not on, it is necessary to check whether the control logic, wiring circuit, and safety valve 8 are faulty. If the start indicator light is on, the simulation debugging is normal, fill in the relevant debugging records, manually close the first valve 4, open thesecond valve 11 to remove excess gas, and restore the system to the state before the test. You can go to the site to start the start-up test (Note: K%=±0.10%, which is the detection accuracy of the remote pressure gauge 15).

7、检查待检安全阀8的台账，查找如上次检测日期、整定压力、密封压力、安装位置等校验记录及报告信息是否齐全；7. Check the ledger of the safety valve 8 to be inspected, and find out whether the calibration records and report information such as the last inspection date, set pressure, sealing pressure, installation position, etc. are complete;

8、对待检安全阀8进行外观检查(安全阀8的铅封是否完好、安全阀8进口前和出口后的阀铅封是否完好并且处于正常开启位置、安全阀8有无泄漏、其外表有无腐蚀情况、爆破片装置是否完好)，并做好记录；8. Check the appearance of the safety valve 8 to be inspected (whether the lead seal of the safety valve 8 is in good condition, whether the valve seals before the inlet and after the outlet of the safety valve 8 are in good condition and in the normal open position, whether the safety valve 8 leaks, and whether its appearance is No corrosion, whether the rupture disc device is in good condition), and make a record;

9、检查控制单元PLC上位机系统安全阀8启跳提示记录是否正常显示；9. Check whether the safety valve 8 of the control unit PLC host computer system is normally displayed;

10、关闭安全阀8进口前手阀或根部阀，以及后手阀(若无后手阀，把安全阀8至泄放缓冲罐的压力降为零)；10. Close the front hand valve or root valve and the rear hand valve at the inlet of safety valve 8 (if there is no rear hand valve, reduce the pressure from safety valve 8 to the relief buffer tank to zero);

11、拆去爆破片及夹持器。11. Remove the rupture disc and holder.

本实施例的安全阀在线检测系统，其解决方案就是在一只待检的安全阀8与压力容器18之间与安全阀8进口连接的根部阀(习惯称之为根部阀)关闭后，安装本实施例中的安全阀在线检测系统的工装，借用高压氮气瓶1提供合适压力的氮气作为检测介质，采用自动调节阀、压力自动检测控制元件等措施对待检安全阀8进行在线启跳(整定)压力和密封试验的检测，不影响在役压力容器18的正常运行，在役压力容器18则通过另一只安全阀17受到超压保护。The solution of the safety valve on-line detection system of the present embodiment is to install the root valve (accustomed to call the root valve) connected to the inlet of the safety valve 8 between the safety valve 8 to be tested and thepressure vessel 18 is closed. The tooling of the safety valve on-line detection system in this embodiment uses a high-pressure nitrogen cylinder 1 to provide nitrogen with a suitable pressure as the detection medium, and adopts measures such as an automatic regulating valve and an automatic pressure detection control element to start the safety valve 8 online (setting). ) The detection of pressure and sealing test does not affect the normal operation of the in-service pressure vessel 18 , and the in-service pressure vessel 18 is protected from overpressure through anothersafety valve 17 .

具体的本实施例中的晶体硅生产装置中的其中一只待检安全阀8的启跳压力是185KPa，进口公称直径等于100mm。Specifically, the starting pressure of one of the safety valves 8 to be inspected in the crystalline silicon production device in this embodiment is 185KPa, and the nominal diameter of the inlet is equal to 100mm.

将待检测安全阀8的安全阀进口与空腔9第一出口连接，把设计制作的安全阀在线检测系统工装安装在安全阀8在用时的带夹持器的爆破片空间位置，并用双头螺栓22和垫片21固定好(采用同样规格的新的螺栓)，通过介质储存单元提供检测用介质；Connect the safety valve inlet of the safety valve 8 to be inspected with the first outlet of the cavity 9, install the designed and manufactured safety valve online inspection system tool in the space position of the bursting disc with the holder when the safety valve 8 is in use, and use a double head Thebolts 22 and the gasket 21 are fixed (new bolts of the same specification are used), and the medium for testing is provided through the medium storage unit;

通过控制单元调节第一阀门4、第二阀门11来控制空腔9内的压力为预设压力，对安全阀8进行在线启跳回落压力的密封试验检测，若在线启跳回落压力的密封试验检测合格，再对安全阀8进行在线回座压力的密封试验检测。该检测方法不影响在役压力容器18的正常运行，压力容器18连接两个安全阀，其中一个使用，一个备用，本实施例对于备用的安全阀8进行在线检测，压力容器18通过使用的安全阀17进行超压保护。The first valve 4 and thesecond valve 11 are adjusted by the control unit to control the pressure in the cavity 9 to be the preset pressure, and the safety valve 8 is subjected to the online jump-back pressure seal test detection. If the online jump-back pressure seal test is performed If the test is qualified, the safety valve 8 is tested by the online reseating pressure sealing test. This detection method does not affect the normal operation of the in-service pressure vessel 18. Thepressure vessel 18 is connected with two safety valves, one of which is used and the other is reserved.Valve 17 provides overpressure protection.

本实施例中的安全阀在线检测系统以及检测方法，特别适用于大型的石油、化工、能源企业连续生产运行的装置中盛装气体或气液混合介质的压力容器18上安装的弹簧式安全阀8的在线检测。现有技术中，在压力容器18上分别安装有两个弹簧式安全阀，一个安全阀8使用，另外一个备用，每个安全阀进口必须有根部阀与压力容器18相连，在根部阀与安全阀8进口之间配带夹持器夹持爆破片或法兰短节。The safety valve on-line detection system and detection method in this embodiment are especially suitable for the spring-type safety valve 8 installed on thepressure vessel 18 containing gas or gas-liquid mixed medium in the continuous production and operation of large-scale petroleum, chemical, and energy enterprises. online detection. In the prior art, two spring-type safety valves are respectively installed on thepressure vessel 18, one safety valve 8 is used, and the other is reserved. Each safety valve inlet must have a root valve connected to thepressure vessel 18, and the root valve is connected to the safety valve. A clamp is provided between the inlets of valve 8 to hold the bursting disc or short flange joint.

优选的是，空腔9的安装位置为待检测的安全阀8与根部阀之间装有带夹持器的爆破片或法兰短节的位置。Preferably, the installation position of the cavity 9 is the position where a bursting disc with a holder or a short flange joint is installed between the safety valve 8 to be tested and the root valve.

优选的是，所述步骤对安全阀8进行在线启跳回落压力的密封试验检测的具体方法为：Preferably, the specific method of performing the sealing test detection of the online jump-back pressure on the safety valve 8 in the step is:

打开第一阀门4、关闭第二阀门11，通过介质储存单元提供检测用介质，当待检测安全阀8启跳回落时，若第一压力检测单元检测到空腔9内的压力为第一预设压力，则控制器联锁控制关闭第一阀门4，并断开第一快接头，自动调节第二阀门11仍处于关闭状态，检测由介质储存单元到安全阀8之间的管路以及零部件、由空腔9到第二阀门11出口的连接管路之间的管路以及零部件的密封点的密封性，具体检测第一快速接头3、第一阀门4、第一球阀5、压力传感器6、第二快速接头7、第二阀门11、垫片21密封点密封性，本实施例中的检测系统在投用前按照高于启跳压力100～150KPa进行了气密试验合格，若第一预设压力在第一预设时间内不变，则密封试验合格，否则密封试验不合格。Open the first valve 4 and close thesecond valve 11, and the medium for detection is provided by the medium storage unit. When the safety valve 8 to be detected jumps and falls back, if the first pressure detection unit detects that the pressure in the cavity 9 is the first predetermined pressure If the pressure is set, the controller will interlock and control to close the first valve 4, disconnect the first quick connector, automatically adjust thesecond valve 11 to remain in the closed state, and detect the pipeline from the medium storage unit to the safety valve 8 and the zero The tightness of the components, the pipelines from the cavity 9 to the outlet of thesecond valve 11 and the sealing points of the components, specifically check the first quick connector 3, the first valve 4, the first ball valve 5, the pressure The sensor 6, the second quick connector 7, thesecond valve 11, and the sealing point of the gasket 21 are sealed. The detection system in this embodiment has been tested for airtightness according to 100-150KPa higher than the starting pressure before being put into use. If the first preset pressure does not change within the first preset time, the sealing test is qualified; otherwise, the sealing test is unqualified.

优选的是，第一预设压力为0.9倍启跳压力*(1+±0.10％)KPa，第一预设时间为3～10分钟。具体的本实施例中的第一预设时间为5分钟。Preferably, the first preset pressure is 0.9 times the starting pressure*(1+±0.10%)KPa, and the first preset time is 3-10 minutes. Specifically, the first preset time in this embodiment is 5 minutes.

优选的是，所述步骤对安全阀8进行在线启跳回落压力的密封试验检测中，若第一压力检测单元检测到空腔9内的压力大于第一预设压力，则通过控制单元打开第二阀门11进行泄压，直至第一压力检测单元检测到空腔9内的压力为第一预设压力，再自动关闭第二阀门11；Preferably, in the said step, in the sealing test detection of the online jump-back pressure of the safety valve 8, if the first pressure detection unit detects that the pressure in the cavity 9 is greater than the first preset pressure, the control unit will open the first pressure Thesecond valve 11 releases pressure until the first pressure detection unit detects that the pressure in the cavity 9 is the first preset pressure, and then automatically closes thesecond valve 11;

若第一压力检测单元检测到空腔9内的压力小于第一预设压力，则通过控制单元打开第一阀门4进行补气，直至第一压力检测单元检测到空腔9内的压力为第一预设压力，再关闭第一阀门4，复查系统中第一快速接头3、第一阀门4、第一球阀5、压力传感器6、第二快速接头7、第二阀门11、垫片21密封点密封性，若第一预设压力在第一预设时间内不变，则密封试验合格，否则密封试验不合格。If the first pressure detection unit detects that the pressure in the cavity 9 is lower than the first preset pressure, the control unit will open the first valve 4 for air supply until the first pressure detection unit detects that the pressure in the cavity 9 is the first A preset pressure, then close the first valve 4, and review the sealing of the first quick connector 3, the first valve 4, the first ball valve 5, the pressure sensor 6, the second quick connector 7, thesecond valve 11, and the gasket 21 in the system. Point sealing, if the first preset pressure does not change within the first preset time, the sealing test is qualified, otherwise the sealing test is unqualified.

优选的是，所述步骤对安全阀8进行在线回座压力的密封试验检测的具体方法为：Preferably, the specific method of performing the sealing test detection of the online reseating pressure on the safety valve 8 in the step is as follows:

打开第一阀门4、关闭第二阀门11，通过介质储存单元提供检测用介质，当待检测安全阀8回座时，若第一压力检测单元检测到空腔9内的压力为第二预设压力，则控制器控制关闭第一阀门4，检测由介质储存单元到安全阀8之间的管路以及零部件、由空腔9到第二阀门11出口的连接管路之间的管路以及零部件的密封点的密封性，具体检测第一快速接头3、第一阀门4、第一球阀5、压力传感器6、第二快速接头7、第二阀门11、垫片21密封点密封性，若第二预设压力在第二预设时间内不变，则密封试验合格，否则密封试验不合格。Open the first valve 4 and close thesecond valve 11, and the medium for detection is provided by the medium storage unit. When the safety valve 8 to be detected is seated, if the first pressure detection unit detects that the pressure in the cavity 9 is the second preset pressure, the controller controls to close the first valve 4, detects the pipeline and components from the medium storage unit to the safety valve 8, the pipeline from the cavity 9 to the connecting pipeline of thesecond valve 11 outlet, and The tightness of the sealing points of the parts, specifically test the tightness of the sealing points of the first quick connector 3, the first valve 4, the first ball valve 5, the pressure sensor 6, the second quick connector 7, thesecond valve 11, and the gasket 21, If the second preset pressure does not change within the second preset time, the sealing test is qualified; otherwise, the sealing test is unqualified.

优选的是，第二预设压力为0.9倍启跳压力*(1+±0.10％)KPa，第二预设时间为3～10分钟。具体的，本实施例中的第二预设时间为5分钟。Preferably, the second preset pressure is 0.9 times the starting pressure*(1+±0.10%)KPa, and the second preset time is 3-10 minutes. Specifically, the second preset time in this embodiment is 5 minutes.

优选的是，在对安全阀8进行在线回座压力时的密封试验检测，若检测结果不合格，所述方法还包括以下步骤：Preferably, when the safety valve 8 is subjected to the sealing test detection during the online reseating pressure, if the detection result is unqualified, the method further includes the following steps:

若安全阀8的阀芯与阀座之间的密封面有颗粒或杂质，则通过氮气对安全阀8的阀芯与阀座之间的密封面吹扫至少两次，再用同样的方法对安全阀8进行在线回座压力的密封试验检测，若还是密封试验不合格，则拆卸安全阀8，修复或更换相应的零件后，重新进行安全阀在线检测系统的密封试验检测。具体的，本实施例中通过氮气对安全阀8的阀芯与阀座之间的密封面吹扫2～3次。If there are particles or impurities on the sealing surface between the valve core and the valve seat of the safety valve 8, purge the sealing surface between the valve core and the valve seat of the safety valve 8 at least twice with nitrogen, and then use the same method to clean the sealing surface between the valve core and the valve seat of the safety valve 8. The safety valve 8 is tested by the online reseating pressure sealing test. If the sealing test is still unqualified, the safety valve 8 shall be disassembled, and the corresponding parts shall be repaired or replaced, and then the sealing test of the online testing system of the safety valve shall be performed again. Specifically, in this embodiment, the sealing surface between the valve core and the valve seat of the safety valve 8 is purged with nitrogen gas for 2-3 times.

本实施例中的安全阀8在线检测启跳压力和密封试验压力方法的在线检测系统概述Overview of the online detection system of the method for online detection of the start-up pressure and the sealing test pressure of the safety valve 8 in this embodiment

1.用以下符号代表各组成部件：1. The components are represented by the following symbols:

P1定义为安全阀8校验启跳压力值，P2定义为密封试验压力值是启跳压力值的0.9倍(假设待检安全阀8的启跳压力都是大于500KPa)，P3、P4分别为第二压力检测单元的两个压力传感器6的实测压力值，具体的，这两个压力传感器6为远传压力变送器，P5为第二压力检测单元压力开关28的实际启跳压力值，压力单位均为Kpa，V1为第一阀门4，V2为第二阀门11，N为高压氮气瓶1，V3为减压阀2，V4为第一球阀5，SV安全阀8，M为空腔9。P1 is defined as the safety valve 8 check tripping pressure value, P2 is defined as the sealing test pressure value is 0.9 times the tripping pressure value (assuming that the tripping pressure of the safety valve 8 to be inspected is greater than 500KPa), P3, P4 are respectively The measured pressure values of the two pressure sensors 6 of the second pressure detection unit, specifically, the two pressure sensors 6 are remote pressure transmitters, and P5 is the actual trigger pressure value of thepressure switch 28 of the second pressure detection unit, The unit of pressure is Kpa, V1 is the first valve 4, V2 is thesecond valve 11, N is the high pressure nitrogen cylinder 1, V3 is thepressure reducing valve 2, V4 is the first ball valve 5, SV safety valve 8, M is the cavity 9.

2.安全阀在线检测系统概述如下：2. An overview of the safety valve online detection system is as follows:

本实施例中的安全阀在线检测系统具有数据采集、过程控制、显示和记录等功能，以及集中显示、操作和管理。硬件控制单元采用西门子300系列PLC模块，主要有电源、CPU、模拟量输出模块、模拟量输出模块、通讯模块(TCP/IP)和触摸屏显示器。可提供DC24V电源，具有两线制仪表4-20mA信号的输入和输出功能，将P3、P4、V1、V2接入PLC模块，控制过程为P3和P4将检测到的压力信号转换成4-20mA信号输入CPU进行运算，CPU运算结果输出控制V1和V2阀，达到控制要求。The safety valve on-line detection system in this embodiment has functions such as data acquisition, process control, display and recording, as well as centralized display, operation and management. The hardware control unit adopts Siemens 300 series PLC module, which mainly includes power supply, CPU, analog output module, analog output module, communication module (TCP/IP) and touch screen display. It can provide DC24V power supply, with input and output functions of 4-20mA signal of two-wire instrument, connect P3, P4, V1, V2 to the PLC module, and the control process is that P3 and P4 convert the detected pressure signal into 4-20mA The signal is input to the CPU for operation, and the CPU operation result is output to control the V1 and V2 valves to meet the control requirements.

安全阀在线检测系统包括：检测单元(变送器)、控制单元(调节器)、执行机构(调节阀)和被控对象，控制单元应用西门子STEP7 V5.5编程软件编写程序建立PID控制器，控制器设定自动和手动两种模式，P1定义为安全阀8试验启跳压力值，P2为控制目标值(密封试验压力值)，P3和P4为压力测量值，P5为实际启跳压力值，V1和V2为被控对象。The safety valve online detection system includes: detection unit (transmitter), control unit (regulator), actuator (regulator valve) and controlled object. The control unit uses Siemens STEP7 V5.5 programming software to write a program to establish a PID controller. The controller sets two modes: automatic and manual. P1 is defined as the safety valve 8 test tripping pressure value, P2 is the control target value (sealing test pressure value), P3 and P4 are the pressure measurement values, and P5 is the actual tripping pressure value. , V1 and V2 are controlled objects.

本安全阀在线检测系统使用西门子300PLC编程软件编写程序实现自动控制，首先建立PID控制器，控制器设定自动和手动两种模式，P2为控制目标值(密封试验压力值)，P1定义为安全阀8校验启跳压力值185KPa，P2为密封试验压力值，P3和P4为压力测量值，P5为实际启跳压力值即启跳压力指示开关，V1和V2为被控对象(有可靠的压力控制与调节装置或者超压报警装置)。This safety valve online detection system uses Siemens 300PLC programming software to write programs to realize automatic control. First, a PID controller is established, and the controller is set to two modes: automatic and manual. P2 is the control target value (sealing test pressure value), and P1 is defined as safety. Valve 8 checks the tripping pressure value of 185KPa, P2 is the sealing test pressure value, P3 and P4 are the pressure measurement values, P5 is the actual tripping pressure value, that is, the tripping pressure indicating switch, and V1 and V2 are the controlled objects (with reliable pressure control and regulation device or overpressure alarm device).

3.待检安全阀8启跳压力检测：开始通氮气，将V1和V2调节阀投自动模式，PID控制器通过运算调节被控对象V1阀，当测量压力P3＝P1(1±2％),P4＝P1(1±2％),安全阀8起跳，启跳压力指示灯亮，则测试结束；P3和P4为压力测量值为P1(1±2％)(因P1>500KPa)，测试结果合格(注：P1(1±2％)为检测安全阀8启跳压力或整定压力的合格范围)。3. Detection of starting pressure of safety valve 8 to be inspected: start to pass nitrogen, put V1 and V2 regulating valves into automatic mode, PID controller adjusts the V1 valve of the controlled object through operation, when the measured pressure P3=P1 (1±2%) , P4=P1 (1±2%), safety valve 8 jumps off, the start pressure indicator light is on, then the test ends; P3 and P4 are the pressure measurement values of P1 (1±2%) (because P1>500KPa), the test result Qualified (Note: P1 (1±2%) is the qualified range for detecting the starting pressure or setting pressure of safety valve 8).

4.待检安全阀8密封试验压力检测：启跳测试合格后，将V1和V2阀控制器投自动模式，PID控制器通过运算调节被控对象V1和V2，结合PID参数的调节，因为P1>300KPa，当测量压力P3>0.9*185KPa(1+±0.10％),P4>0.9*185KPa(1+±0.10％),控制器调节V2阀泄压，当测量压力P3<0.9*185KPa(1+±0.10％),P4<0.9*185KPa(1+±0.10％),控制器调节V1阀进行充气，直到P3和P4压力控制范围无限接近0.9*185KPa(1+±0.10％)，使检测系统进行入稳态状态，误差范围为±0.10％*185,当0.9*185KPa(1+±0.10％)＝P3和P4＝0.9*185KPa(1+±0.10％)时控制器将V1和V2阀关至0％，模式调整为手动模式，开始密封试验，经过T时间如5分钟后，若0.9*185KPa(1+±0.10％)＝P3和P4＝0.9*185KPa(1+±0.10％),持续观察1分钟，压力值无变化，则安全阀8的密封试验合格，密封试验结束；若经过T时间如5分钟后，持续观察1分钟，P3/P4缓慢持续下降，可能是密封不严，若P3/P4急剧下降，可能是未回座或出现卡涩或错位，停止检测，拆卸安全阀8修复后重新进行检测。4. Pressure detection of the sealing test of the safety valve 8 to be inspected: After the start-up test is qualified, the V1 and V2 valve controllers are put into automatic mode, and the PID controller adjusts the controlled objects V1 and V2 through operation, combined with the adjustment of PID parameters, because P1 >300KPa, when the measured pressure P3>0.9*185KPa(1+±0.10%), P4>0.9*185KPa(1+±0.10%), the controller adjusts the V2 valve to release the pressure, when the measured pressure P3<0.9*185KPa(1 +±0.10%), P4<0.9*185KPa (1+±0.10%), the controller adjusts the V1 valve to inflate until the pressure control range of P3 and P4 is infinitely close to 0.9*185KPa (1+±0.10%), so that the detection system Enter the steady state, the error range is ±0.10%*185, when 0.9*185KPa (1+±0.10%)=P3 and P4=0.9*185KPa (1+±0.10%), the controller will close the V1 and V2 valves to 0%, adjust the mode to manual mode, start the sealing test, after T time such as 5 minutes, if 0.9*185KPa(1+±0.10%)=P3 and P4=0.9*185KPa(1+±0.10%), continue Observe for 1 minute, and the pressure value does not change, then the sealing test of safety valve 8 is qualified, and the sealing test is over; if the T time, such as 5 minutes, continues to observe for 1 minute, P3/P4 continues to decrease slowly, it may be that the sealing is not tight. P3/P4 drops sharply, it may be that it is not seated or jammed or misplaced, stop the test, remove the safety valve 8 and repair it and perform the test again.

本实施例中的安全阀在线检测系统及检测方法，实现了安全阀8在线检测密封试验压力，使用外加氮气作为试验介质，能对易燃易爆有毒有害气体及流体中含有颗粒或杂质的介质进行检测，用于在线检测安全阀8的密封试验压力值。The online detection system and detection method of the safety valve in this embodiment realizes the online detection of the sealing test pressure of the safety valve 8, and the use of external nitrogen as the test medium can prevent flammable, explosive, toxic and harmful gases and the medium containing particles or impurities in the fluid. Detecting is used to detect the sealing test pressure value of the safety valve 8 online.

现有技术中安全阀8在线检测仪在安全起跳和回座时对压力容器18内流体有一定的扰动影响，即压力容器18内流体出现扰动现象，主要体现在液位、压力的波动，对生产工艺的平稳操作调节带来麻烦，不利于安全稳定生产，会给现场检测人员带来潜在的安全风险。本实施例的安全阀8在线检测不会出现此问题，本实施例对安全阀8进行在线检测，使用外加氮气作为试验介质，与在用压力容器18介质无关，压力容器18内流体无扰动现象，有利于生产工艺的平稳操作调节，有利于安全稳定生产，保证了现场检测人员安全。In the prior art, the on-line detector of the safety valve 8 has a certain disturbance effect on the fluid in thepressure vessel 18 during safe take-off and return, that is, the fluid in thepressure vessel 18 is disturbed, which is mainly reflected in the fluctuation of the liquid level and pressure. The smooth operation and adjustment of the production process brings trouble, is not conducive to safe and stable production, and will bring potential safety risks to on-site inspection personnel. The online detection of the safety valve 8 in this embodiment will not cause this problem. In this embodiment, the online detection of the safety valve 8 uses the external nitrogen as the test medium, which has nothing to do with the medium of thepressure vessel 18 in use, and the fluid in thepressure vessel 18 is not disturbed. , is conducive to the smooth operation and adjustment of the production process, is conducive to safe and stable production, and ensures the safety of on-site inspection personnel.

对在役压力容器18设备运行中的安全阀8所出现密封面有颗粒或杂质而出现泄漏的问题进行在线应急处理，对申请延期一年以上长周期运行的安全阀8进行不停车在线进行启跳压力和密封压力的检测，满足相关法律法规要求，符合相关主管部门对在用安全阀8每年至少校验一次的要求。安全阀8在线检测减少了拆卸、运输、吊装、回装的环节，既能缩短检测时间，又能节省费用。On-line emergency treatment is carried out for the leakage of particles or impurities on the sealing surface of the safety valve 8 during the equipment operation of the in-service pressure vessel 18, and the safety valve 8 that applies for an extension of more than one year for long-term operation shall be restarted online without stopping. The detection of jumping pressure and sealing pressure meets the requirements of relevant laws and regulations, and meets the requirements of relevant competent authorities for the safety valve 8 in use to be calibrated at least once a year. The online inspection of safety valve 8 reduces the steps of disassembly, transportation, hoisting, and reassembly, which can not only shorten the inspection time, but also save costs.

当安全阀8在常温、常压下进行离线冷态校验时，利用安全阀在线检测系统可以解决如下现场实际问题：When the safety valve 8 is subjected to offline cold state verification at normal temperature and pressure, the use of the safety valve online detection system can solve the following practical problems on site:

①为了节省大检修时间，大检修开始停车前筛选出不需要检修的安全阀8进行在线检测，尤其是大口径、安装位置高的安全阀8计划安排在非大检修时进行在线检测，既为大修节省时间，又减少了拆卸、吊装、安全的工期和费用(以目前某晶体硅3.6万吨/年项目精馏单元口径大于80毫米，安装位置特殊的安全阀8为例，通过测算，每年节省吊车等辅助费用至少30万元。)；①In order to save the time for overhaul, the safety valves 8 that do not need to be overhauled are screened out for on-line inspection before the overhaul starts. The overhaul saves time, and reduces the construction period and cost of dismantling, hoisting, and safety (taking the safety valve 8 with the diameter of the distillation unit larger than 80 mm and the installation position of a 36,000-ton/year crystalline silicon project as an example, through calculation, the annual Save at least 300,000 yuan in auxiliary costs such as cranes.);

②若在离线校验台整定后的安全阀8经运输、就位安装等环节的影响安全阀8的启跳压力往往发生变化，对此，利用本实施例设计的检测系统和方法在投料开车前对此安全阀8进行再次启跳压力和密封压力的检测；2. If the safety valve 8 after being set on the off-line calibration bench is affected by the links such as transportation and in-situ installation, the tripping pressure of the safety valve 8 tends to change. In this regard, the detection system and method designed in this embodiment are used in the feeding and driving. Before this safety valve 8 is checked again for the start-up pressure and sealing pressure;

③对由于安全阀8的弹簧刚度太大引起安全阀8出现阀瓣频跳或颤振，在现场改用刚度适当的弹簧后，对安全阀8进行启跳和密封的在线检测；或安全阀8的调节圈调整不当，使回座压力过高引起安全阀8出现阀瓣频跳或振动，通过重新调整调节圈位置后，再次在线进行启跳和密封检测。③ If the spring stiffness of the safety valve 8 is too large, the valve flap or flutter occurs in the safety valve 8. After switching to a spring with an appropriate stiffness on site, conduct on-line testing of the safety valve 8 for start-up and sealing; or the safety valve The adjustment ring of 8 is improperly adjusted, so that the reseating pressure is too high, which causes the valve disc to jump or vibrate.

本实施例中的安全阀在线检测系统及检测方法检测精确度高，误差因素减至最小。通过选用精度等级较高的仪器、合理标定检测仪，等办法，提高检测准确度。The safety valve on-line detection system and detection method in this embodiment have high detection accuracy and minimize error factors. The detection accuracy can be improved by selecting instruments with higher accuracy grades, rationally calibrating the detectors, etc.

选择设计压力传感器6和压力开关28既能现场显示，又能远传进入PLC自动控制系统，并设置启跳压力在允许偏差内进行声光警示，既有视觉感知，又有听觉的感知；并且在正式投用前完成检测系统的回路测试和模拟联调，这样能安全有效的避免了安全阀8拉起过量，而导致安全阀8开启后不回座、介质过度流失等安全隐患，科学地实现了检测过程对工况没有扰动，保证了现场检测工作和检验人员的安全性。The pressure sensor 6 and thepressure switch 28 are selected and designed to be displayed on-site, and can be remotely transmitted into the PLC automatic control system, and the start-up pressure is set to give sound and light warning within the allowable deviation, which has both visual perception and auditory perception; and Complete the loop test and simulated joint debugging of the detection system before it is officially put into use, which can safely and effectively prevent the safety valve 8 from being pulled too much, resulting in the safety valve 8 not returning to the seat after opening, excessive medium loss and other safety hazards, scientifically It realizes that the detection process has no disturbance to the working conditions, and ensures the safety of on-site detection work and inspection personnel.

可以理解的是，以上实施方式仅仅是为了说明本发明的原理而采用的示例性实施方式，然而本发明并不局限于此。对于本领域内的普通技术人员而言，在不脱离本发明的精神和实质的情况下，可以做出各种变型和改进，这些变型和改进也视为本发明的保护范围。It can be understood that the above embodiments are only exemplary embodiments adopted to illustrate the principle of the present invention, but the present invention is not limited thereto. For those skilled in the art, without departing from the spirit and essence of the present invention, various modifications and improvements can be made, and these modifications and improvements are also regarded as the protection scope of the present invention.