Pressure stabilizer spray valve flow characteristic test device and method covering full flow conditions

Abstract

A test apparatus and method for the flow characteristics of a pressure regulator spray valve covering all flow conditions is disclosed, comprising a main circuit system, a test system, and a water supply system. This application enables automatic switching of the flow meter with the corresponding range based on the measured value, achieving cross-validation of measurement data and continuous, stable, and high-precision measurement. It can simulate the actual operating conditions of the spray valve and measure its flow characteristics under different conditions. It is applicable not only to pressure regulator spray valves but also to regulating valves in wind power, thermal power, chemical, and petroleum industries.

Description

Technical Field

[0001] This invention relates to the field of flow characteristic testing equipment, and specifically to a test device and method for the flow characteristics of a pressure regulator spray valve that covers all flow conditions. Background Technology

[0002] As a key component for spray flow control, the reliability and stability of the pressure regulator spray valve directly affect the system's operating efficiency and safety. Accurate measurement of its flow characteristics is fundamental for optimizing spray system control, fault diagnosis, and energy efficiency assessment. From continuous spraying at low flow rates to full-flow spraying with the valve fully open, the spray flow rate varies widely and significantly. Currently used flow measurement methods struggle to maintain high accuracy across the entire range. In the low-flow range, the small flow signal is susceptible to noise interference, leading to increased measurement errors; in the high-flow range, the flow rate may approach or exceed the upper limit, posing a risk of saturation or damage. This invention proposes a spray valve flow measurement test device and method suitable for continuous spraying to full-flow conditions. This device can accurately control the temperature, pressure, and flow rate of the spray valve under various operating conditions and achieve high-precision, continuous, and stable measurement across the entire flow range of the spray valve. Summary of the Invention

[0003] The purpose of this invention is to provide a test apparatus and method suitable for testing the flow characteristics of a pressure regulator spray valve. The test apparatus comprises three subsystems: a main loop system, a test system, and a water supply system. The main loop system consists of a circulating pump, a pressure regulator, a loop heater, and a loop cooler. The heater heats the system, the cooler cools the system, and the pressure regulator stabilizes the system pressure. The test system consists of a spray valve and multiple flow meters, which can automatically switch flow meters according to the measured flow range.

[0004] The technical solution of the present invention is as follows: a test device for the flow characteristics of a pressure regulator spray valve covering all flow conditions, comprising a main circuit system, a test system and a water supply system; The water replenishment system includes a water replenishment tank, a water replenishment pump, and a booster pump. The water replenishment tank is connected to an external deionized water source and is connected to the water replenishment pump and the booster pump. Both the water replenishment pump and the booster pump are connected to the first shut-off valve, which is connected to the main circuit system through a pipeline. The main loop system includes a cooler, a main circulation pump, a voltage regulator, a heater, and a first electric regulating valve. The first shut-off valve is connected to the cooler and the main circulation pump through a pipeline. The cooler and the main circulation pump are both connected to the heater through pipelines. The first electric regulating valve and the first flow meter are located on the pipeline connecting the main circulation pump and the heater. The cooler is also connected to the voltage regulator, and the heater is connected to the test system through a pipeline. The test system includes a test branch and a flow regulation branch connected in parallel with it. A spray valve test piece is installed in series on the test branch.

[0005] The pressure is steadily increased to the initial value required for the test by using a water supply pump and a booster pump.

[0006] The voltage regulator uses electric heating or spraying to ensure stable pressure in the main circuit; the heater and cooler are used to heat up and cool down the circuit medium, respectively.

[0007] A second electric regulating valve is installed on the flow regulation branch, and a second flow meter is connected in series. By adjusting the opening of the second electric regulating valve, the flow rate is changed, thereby controlling the proportion of flow entering the test branch.

[0008] The test branch is connected in parallel with a third, fourth, and fifth flow meter. Each of these three flow meters is equipped with a corresponding second, third, and fourth shut-off valve to control the on / off of the measurement channel of each flow meter. The flow ranges of the third, fourth, and fifth flow meters are arranged from small to large.

[0009] A test method for the flow characteristics of a pressure regulator spray valve covering all flow conditions includes the following steps: S1: Determine the operating conditions required for the test, including the test temperature T and pressure P; S2: Open the first shut-off valve, start the water supply pump and booster pump to inject deionized water into the entire device, continue to pressurize to above pressure P, close the first shut-off valve, and isolate the water supply system; S3: Start the main circulation pump, adjust the flow rate of the main circulation pump through the electric regulating valve and flow meter, start the heater and pressure stabilizer, so that the temperature of the entire device rises to T and the pressure P is kept stable. S4: Gradually adjust the opening of the spray valve test piece in the order of small flow rate to large flow rate, and at the same time adjust the opening of the second electric regulating valve to control the bypass flow rate ratio.

[0010] In step S2, after the pressure is increased to pressure P, a tightness check is performed.

[0011] In step S4, during the low flow rate stage, based on the estimated flow rate, the second shut-off valve is opened, and the third and fourth shut-off valves are closed, with the third flow meter controlling the flow rate measurement of the test branch.

[0012] In step S4, when it is determined that the flow rate value has stably entered the better measurement range of the fourth flow meter, the third shut-off valve is opened first. After confirming that the reading of the fourth flow meter is stable and that the reading of the third flow meter is within the allowable error range, the second shut-off valve is closed.

[0013] In step S4, when the flow rate continues to increase to the full flow condition, a switch is executed from the fourth flow meter to the fifth flow meter.

[0014] In step S4, if the reading of any of the three, four, or five flow meters exceeds 90% of its full capacity during the measurement process, the system will issue a warning signal, prompting the user to switch to a flow meter branch with a higher capacity.

[0015] The significant advantages of this invention are: a) The present invention designs a test device for measuring the flow rate of a spray valve covering operating conditions from small flow rate to full flow rate. The test device mainly includes a main circuit system, a spray valve flow rate measurement test system based on a combination of multiple flow meters, and a water replenishment system.

[0016] b) The test device designed by this invention can automatically switch the flow meter of the corresponding range according to the measured value, and can realize cross-verification of measurement data and continuous, stable and high-precision measurement.

[0017] c) The test device designed by this invention can simulate the actual operating conditions of the spray valve and measure its flow characteristics under different operating conditions.

[0018] e) The test apparatus and method designed in this invention are not only applicable to voltage regulator spray valves, but also to regulating valves in fields such as wind power, thermal power, chemical industry, and petroleum.

[0019] In summary, this method can effectively diagnose the fault status of electric valves and can also be applied to the flow characteristic test of regulating valves in nuclear power, wind power, thermal power, chemical industry, petroleum and other fields. Attached Figure Description

[0020] Figure 1 Schematic diagram of the spray valve flow characteristic test device; Figure 2 Schematic diagram of the test method for the flow characteristics of a spray valve; The markings in the diagram and their corresponding component names are as follows: 1-Water replenishment tank; 2-Water replenishment pump; 3-Booster pump; 4-Cooler; 5-Main circulation pump; 6-Pressure stabilizer; 7-Heater; 8-Spray valve test piece.

[0021] 21-First electric regulating valve; 22-Second electric regulating valve.

[0022] 31-First flow meter; 32-Second flow meter; 33-Third flow meter; 34-Fourth flow meter; 35-Fifth flow meter.

[0023] 41-First shut-off valve; 42-Second shut-off valve; 43-Third shut-off valve; 44-Fourth shut-off valve; 45-Fifth shut-off valve. Detailed Implementation

[0024] Many specific details are set forth in the following description to provide a full understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of this application; therefore, this application is not limited to the specific embodiments disclosed below.

[0025] The terminology used in one or more embodiments of this application is for the purpose of describing particular embodiments only and is not intended to limit the scope of one or more embodiments of this application. The singular forms “a,” “the,” and “the” used in one or more embodiments of this application and in the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” used in one or more embodiments of this application refers to and includes any or all possible combinations of one or more associated listed items.

[0026] It should be understood that although the terms first, second, etc., may be used to describe various information in one or more embodiments of this application, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, first may also be referred to as second without departing from the scope of one or more embodiments of this application, and similarly, second may also be referred to as first.

[0027] The specific technical content of the present invention will now be described with reference to the accompanying drawings; A test device for the flow characteristics of a pressure regulator spray valve covering all flow conditions includes a main circuit system, a test system, and a water supply system.

[0028] The water supply system is used to provide deionized water to the main circuit and test system and to establish initial pressure. For example... Figure 1 As shown, the water replenishment system includes a water replenishment tank 1, a water replenishment pump 2, and a booster pump 3. The water replenishment tank 1 is connected to an external deionized water source and is connected to the water replenishment pump 2 and the booster pump 3. Both the water replenishment pump 2 and the booster pump 3 are connected to a first shut-off valve 41, which is connected to the main circuit system through a pipeline. The water supply pump 2 and the booster pump 3 can steadily increase the system pressure to the initial value required for the test. The first shut-off valve 41 serves as an isolation valve between the water supply system and the main circuit system, used to connect the circuit during the water supply and pressurization phase and to isolate the water supply side during the test operation phase.

[0029] The main loop system provides a stable high-temperature and high-pressure environment for the spray valve test. This system includes a cooler 4, a main circulation pump 5, a pressure regulator 6, a heater 7, and a first electrically controlled regulating valve 21. A first shut-off valve 41 is connected to the cooler 4 and the main circulation pump 5 via pipelines. Both the cooler 4 and the main circulation pump 5 are connected to the heater 7 via pipelines. The connecting pipeline between the main circulation pump 5 and the heater 7 contains the first electrically controlled regulating valve 21 and a first flow meter 31. The cooler 4 is also connected to the pressure regulator 6, and the heater 7 is connected to the test system via pipelines. The main circulation pump 5 is used to drive the high-temperature and high-pressure medium to circulate within the main loop system, overcoming system resistance. A first flow meter 31 is installed on the outlet pipe of the main circulation pump 5 to monitor the total circulation flow of the main loop in real time. The pressure regulator 6 precisely controls the system pressure through electric heating or spraying, ensuring that the main loop pressure remains stable at the target value even when changes in the spray valve opening cause flow fluctuations. P MPa. Heater 7 and cooler 4 are used for heating and cooling the circuit medium, respectively. During the test preparation stage, heater 7 is started to heat the medium to the target temperature T ℃; when the test is completed or cooling is required, cooler 4 is activated for rapid cooling. The first electric regulating valve 21 is installed on the main circuit pipeline to assist in regulating the back pressure and total flow distribution of the main circuit system.

[0030] The test system includes a test branch and a flow regulation branch connected in parallel. A second electrically operated regulating valve 22 is installed on the flow regulation branch, and a second flow meter 32 is connected in series. By adjusting the opening of the second electrically operated regulating valve 22, the bypass flow through this branch can be changed, thereby indirectly controlling the proportion of flow entering the test branch and helping to achieve the flow coverage requirement within the full opening range of the spray valve. The second flow meter 32 is used to accurately measure the real-time flow of this regulating branch.

[0031] A spray valve test piece 8 is installed in series on the test branch, and three flow meters with different ranges—the third flow meter 33, the fourth flow meter 34, and the fifth flow meter 35—are connected in parallel. Each of these three flow meters is equipped with a corresponding branch switching shut-off valve (the second shut-off valve 42, the third shut-off valve 43, and the fourth shut-off valve 44) to control the on / off state of each flow meter's measurement channel. The spray valve test piece 8, as the test object, is installed on the main pipeline of the test branch. The flow ranges of the third flow meter 33, the fourth flow meter 34, and the fifth flow meter 35 are arranged from smallest to largest.

[0032] The experimental device designed for this invention, combined with Figure 2 The test flowchart further introduces the test method for measuring the flow characteristics of the spray valve across the entire flow range.

[0033] a) Determination of test conditions Before conducting the test, the basic operating conditions required for the test need to be determined, including the test temperature T (°C) and pressure P (MPa).

[0034] b) Circuit water replenishment and pressure testing Open the air vents at all high points in the circuit, open the first shut-off valve 41 between the water replenishment system and the main circuit system, and start the water replenishment pump 2 and booster pump 3 to inject deionized water into the system. After the air in the system is exhausted and the system is full of water, close the air vents and continue to pressurize to above the required test pressure value to check for tightness and confirm that there are no leaks at any connection. During the water replenishment and pressurization process, all valves in the circuit and test branch should be open or adjusted to the specified state. After the pressure test is passed, close the first shut-off valve 41 to isolate the water replenishment system.

[0035] c) Circuit temperature and pressure increase After water replenishment and pressurization are completed, start the main circulation pump 5. Adjust the flow rate of the main circulation pump 5 through the electric regulating valve 21 and the flow meter 31. Start the heater 7 and the pressure regulator 6, and begin heating and pressurizing at the determined test operating point as the target point. The circuit temperature rises to... T ℃ P Maintain stable system operation at MPa.

[0036] d) Spray valve flow measurement After the operating conditions stabilize, the opening of the spray valve test piece 8 is gradually adjusted in order from small flow rate to large flow rate, while simultaneously adjusting the opening of the second electric regulating valve 22 to control the bypass flow ratio. In the small flow rate stage, the data processing system automatically opens the second shut-off valve 42 (corresponding to the low-range third flow meter 33) and closes the third shut-off valve 43 and the fourth shut-off valve 44, based on the estimated flow rate, allowing the third flow meter 33 to dominate the flow measurement of the test branch. As the opening of the spray valve 8 increases, the flow rate of the test branch gradually enters the overlapping range of the third flow meter 33 and the fourth flow meter 34. The measurement and control system collects flow data in real time. When it determines that the flow value has stably entered the optimal measurement range of the fourth flow meter 34, it automatically issues a command: first, open the third shut-off valve 43; after confirming that the reading of the fourth flow meter 34 is stable and within the allowable error range of the third flow meter 33 (completing cross-verification), then close the second shut-off valve 42, achieving a smooth and uninterrupted switch of measurement control. Similarly, when the flow rate continues to increase to the full flow condition, the system will again execute the switching logic from the fourth flow meter 34 to the fifth flow meter 35. During the measurement process, if the reading of any in-use flow meter exceeds 90% of its full scale, the system will issue a warning signal to prompt the operator to pay attention or forcibly switch to a flow meter branch with a higher flow range.

[0037] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0038] It should be noted that, for the sake of simplicity, the foregoing method embodiments are all described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, as some steps may be performed in other orders or simultaneously according to this application. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions and modules involved are not necessarily essential to this application.

[0039] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0040] The preferred embodiments disclosed above are merely illustrative of this application. The optional embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this application. These embodiments are selected and specifically described in this application to better explain the principles and practical applications of this application, thereby enabling those skilled in the art to better understand and utilize this application.

Claims

1. A test device for the flow characteristics of a pressure regulator spray valve covering the full flow condition, characterized in that: Includes the main circuit system, testing system, and water supply system; The water replenishment system includes a water replenishment tank (1), a water replenishment pump (2), and a booster pump (3). The water replenishment tank (1) is connected to an external deionized water source and is connected to the water replenishment pump (2) and the booster pump (3). The water replenishment pump (2) and the booster pump (3) are both connected to the first shut-off valve (41). The first shut-off valve (41) is connected to the main circuit system through a pipeline. The main circuit system includes a cooler (4), a main circulation pump (5), a voltage regulator (6), a heater (7), and a first electric regulating valve (21). The first shut-off valve (41) is connected to the cooler (4) and the main circulation pump (5) through a pipeline. The cooler (4) and the main circulation pump (5) are both connected to the heater (7) through pipelines. The first electric regulating valve (21) and the first flow meter (31) are located on the pipeline connecting the main circulation pump (5) and the heater (7). The cooler (4) is also connected to the voltage regulator (6), and the heater (7) is connected to the test system through a pipeline. The test system includes a test branch and a flow regulation branch connected in parallel with it. A spray valve test piece (8) is installed in series on the test branch.

2. The test device for the flow characteristics of a spray valve of a pressure regulator covering the full flow condition according to claim 1, characterized in that: The pressure is steadily increased to the initial value required for the test by the water supply pump (2) and the booster pump (3).

3. The test device for the flow characteristics of a spray valve of a pressure regulator covering the full flow condition according to claim 1, characterized in that: The voltage regulator (6) uses electric heating or spraying to ensure the main circuit pressure is stable; the heater (7) and cooler (4) are used to heat up and cool down the circuit medium, respectively.

4. The test device for the flow characteristics of a spray valve of a pressure regulator covering the full flow condition according to claim 1, characterized in that: A second electric regulating valve (22) is installed on the flow regulating branch and a second flow meter (32) is connected in series. By adjusting the opening of the second electric regulating valve (22), the flow rate is changed, thereby controlling the proportion of flow entering the test branch.

5. The pressure regulator spray valve flow characteristic test device covering full flow conditions according to claim 4, characterized in that: The test branch is connected in parallel with the third flow meter (33), the fourth flow meter (34), and the fifth flow meter (35), and is equipped with the corresponding second shut-off valve (42), the third shut-off valve (43), and the fourth shut-off valve (44) to control the opening and closing of the measurement channels of each flow meter. The ranges of the third flow meter (33), the fourth flow meter (34), and the fifth flow meter (35) are arranged from small to large.

6. A test method for the flow characteristics of a pressure regulator spray valve covering all flow conditions, using the apparatus described in claim 5, characterized in that: Includes the following steps: S1: Determine the operating conditions required for the test, including the test temperature T and pressure P; S2: Open the first shut-off valve (41), start the water supply pump (2) and booster pump (3) to inject deionized water into the entire device, continue to pressurize to pressure P, close the first shut-off valve (41) and isolate the water supply system; S3: Start the main circulation pump (5), adjust the flow rate of the main circulation pump (5) through the electric regulating valve (21) and the flow meter (31), start the heater (7) and the pressure regulator (6) to raise the temperature of the whole device to T and keep the pressure P stable. S4: Gradually adjust the opening of the spray valve test piece (8) in the order of small flow rate to large flow rate, and at the same time adjust the opening of the second electric regulating valve (22) to control the bypass flow rate ratio.

7. The test method for the flow characteristics of a voltage regulator spray valve covering all flow conditions according to claim 6, characterized in that: In step S2, after the pressure is increased to pressure P, a tightness check is performed.

8. The test method for the flow characteristics of a voltage regulator spray valve covering all flow conditions according to claim 7, characterized in that: In S4, during the low flow rate stage, based on the estimated flow rate, the second shut-off valve (42) is opened, and the third shut-off valve (43) and the fourth shut-off valve (44) are closed, with the third flow meter (33) taking the lead in measuring the flow rate of the test branch.

9. The test method for the flow characteristics of a voltage regulator spray valve covering all flow conditions according to claim 8, characterized in that: In S4, when it is determined that the flow rate value has stably entered the better measurement range of the fourth flow meter (34), the third shut-off valve (43) is opened first, and after confirming that the reading of the fourth flow meter (34) is stable and the reading of the third flow meter (33) is within the allowable error range, the second shut-off valve (42) is closed.

10. The test method for the flow characteristics of a pressure regulator spray valve covering all flow conditions according to claim 9, characterized in that: In S4, when the flow rate continues to increase to the full flow condition, a switch is executed from the fourth flow meter (34) to the fifth flow meter (35).

11. The test method for the flow characteristics of a voltage regulator spray valve covering all flow conditions according to claim 8, characterized in that: In S4, during the measurement process, if the reading of any of the three flow meters (33), the fourth flow meter (34), and the fifth flow meter (35) exceeds 90% of its full range, the system will issue a warning signal to prompt switching to a flow meter branch with a higher range.

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