Method for detecting valve internal leakage based on ultrasonic and temperature information

Abstract

The application discloses a detection method for judging valve internal leakage based on ultrasonic wave and temperature information, relates to the technical field of valve detection, and solves the technical problem that the prior art is difficult to accurately detect specific conditions of valve internal leakage by judging valve internal leakage conditions according to senses and experience; the application judges whether valve internal leakage characteristics are met through analysis of the internal leakage characteristic values of the valve; then, whether the valve has internal leakage is verified by combining the internal leakage characteristic values of the upstream and downstream, and the leakage condition of the valve is estimated; the application can monitor whether the valve has internal leakage in real time, and prevent safety accidents; after the valve internal leakage is determined, the application estimates the leakage amount by combining the difference between the internal leakage characteristic values of the upstream and downstream and the internal leakage characteristic value-leakage amount contrast relation established in advance; the application can master the leakage loss according to the leakage amount, and can also adjust and optimize the conveying process of the natural gas station.

Description

Technical Field

[0001] This invention belongs to the field of valve testing and relates to valve internal leakage detection technology in natural gas stations. Specifically, it is a detection method for determining valve internal leakage based on ultrasonic waves and temperature information. Background Technology

[0002] Natural gas stations have a large annual gas transmission volume, and each station is equipped with metering equipment to provide users with trade settlement for gas supply. Due to issues with valve manufacturing processes and valve operation and maintenance, some operating valves have leaks, mainly of the types of external and internal leakage.

[0003] While various methods exist for detecting and identifying external valve leaks, and the technology is relatively mature, internal leaks in certain venting valves can directly impact a company's supply chain management, leading to economic losses and resource waste. Furthermore, internal leaks in critical valves on main pipelines severely affect related operations and personnel safety. Because internal valve leaks occur inside the pipeline, they are difficult to detect, often relying on sensory perception and experience, which lacks scientific basis and is prone to misjudgment and underestimation. Currently, no scientifically effective detection method has been established. Therefore, there is an urgent need for a detection method for valve internal leaks based on ultrasonic waves and temperature information. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art; to this end, the present invention proposes a detection method for determining valve internal leakage based on ultrasonic and temperature information, which is used to solve the technical problem that the prior art relies on sensory perception and experience to judge the valve internal leakage, making it difficult to accurately detect the specific situation of valve internal leakage.

[0005] To achieve the above objectives, a first aspect of the present invention provides a method for detecting internal leakage in a valve based on ultrasonic waves and temperature information, comprising:

[0006] The system continuously collects internal leakage characteristic data of the valve; it then converts and processes the internal leakage characteristic data to obtain internal leakage characteristic values; when the internal leakage characteristic value is greater than the internal leakage characteristic threshold, it forces the collection of upstream and downstream internal leakage characteristic data of the valve; the internal leakage characteristic data includes acoustic data or temperature data.

[0007] Simultaneously collect internal leakage characteristic data of the upstream and downstream of the valve, and determine whether the valve has internal leakage based on the characteristic difference between the corresponding internal leakage characteristic values ​​of the upstream and downstream of the valve; if yes, issue an early warning and estimate the leakage amount based on the characteristic difference; if no, continue to monitor the valve.

[0008] Preferably, the cyclically collected internal leakage characteristic data of the valve includes:

[0009] Acoustic and temperature signals are acquired using an integrated ultrasonic temperature sensor; and the pre-processed acoustic and temperature signals are then input into the signal acquisition module.

[0010] The signal acquisition module uses a built-in ADC to cyclically acquire acoustic and temperature signals to obtain internal leakage characteristic data; the cyclic acquisition frequency is 5kHz.

[0011] Preferably, the preprocessing of the acoustic signal includes amplification and filtering; and the filtering process removes acoustic signals other than the 40kHz frequency.

[0012] Preferably, the step of transforming the internal leakage feature data to obtain internal leakage feature values ​​includes:

[0013] Extract acoustic and temperature data from the internal leakage feature data;

[0014] The acoustic data is converted into corresponding encoded values, and the corresponding decibel values ​​are obtained by combining the scaling factor; and the temperature data is converted into temperature values.

[0015] Preferably, when the internal leakage characteristic value is greater than the internal leakage characteristic threshold, the upstream and downstream internal leakage characteristic data of the valve are forcibly collected, including:

[0016] When both the decibel value and the temperature value exceed a certain threshold, the valve is determined to meet the leakage characteristics; the decibel and temperature thresholds are set empirically.

[0017] The ultrasonic temperature sensors upstream and downstream of the valve are forcibly activated to collect internal leakage characteristic data.

[0018] Preferably, the step of synchronously collecting internal leakage characteristic data of the upstream and downstream of the valve, and determining whether the valve has internal leakage based on the characteristic difference between the corresponding internal leakage characteristic values ​​of the upstream and downstream of the valve, includes:

[0019] Extract decibel and temperature values ​​from the internal leakage characteristic values;

[0020] Compare the decibel and temperature values ​​of the upstream and downstream valves to obtain the decibel difference and temperature difference; when both the decibel difference and temperature difference correspond to the difference threshold, it is determined that the valve has internal leakage.

[0021] Preferably, after determining that the valve has internal leakage, the leakage amount is estimated based on the characteristic difference, including:

[0022] Extract decibel or temperature difference values ​​from the characteristic differences;

[0023] The leakage amount is obtained by matching the decibel difference or temperature difference with the internal leakage characteristic value and the leakage amount correlation, and the early warning is given in combination with the leakage amount.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. This invention analyzes the internal leakage characteristic values ​​of valves to determine whether they meet the characteristics of internal leakage; then, it combines the internal leakage characteristic values ​​of upstream and downstream valves to verify whether internal leakage has occurred and to predict the leakage situation of valves; this invention can monitor whether internal leakage has occurred in valves in real time and prevent safety accidents from happening.

[0026] 2. After determining the internal leakage of the valve, this invention uses the difference in internal leakage characteristic values ​​between upstream and downstream to jointly establish a correlation between internal leakage characteristic values ​​and leakage amount to predict the leakage amount. This invention can grasp the leakage loss based on the leakage amount and can also adjust and optimize the transmission process of the natural gas station. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the method steps of the present invention;

[0029] Figure 2 This is a schematic diagram of the decibel value calculation steps of the present invention;

[0030] Figure 3 This is a schematic diagram of the valve upstream and downstream internal leakage characteristic value determination steps of the present invention. Detailed Implementation

[0031] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Please see Figures 1 to 2 The first aspect of the present invention provides a method for detecting internal leakage of a valve based on ultrasonic waves and temperature information, comprising: cyclically collecting internal leakage characteristic data of the valve; converting and processing the internal leakage characteristic data to obtain internal leakage characteristic values; when the internal leakage characteristic value is greater than the internal leakage characteristic threshold, forcibly collecting internal leakage characteristic data of the upstream and downstream of the valve; simultaneously collecting internal leakage characteristic data of the upstream and downstream of the valve, and determining whether the valve has internal leakage based on the characteristic difference between the corresponding internal leakage characteristic values ​​of the upstream and downstream of the valve; if yes, issuing an early warning and estimating the leakage amount based on the characteristic difference; if no, continuously detecting the valve.

[0033] The detection method disclosed in this invention is mainly accomplished through a signal analysis module and a signal acquisition module that communicates with and / or is electrically connected to it. The signal acquisition module collects internal leakage characteristic data through an integrated ultrasonic temperature sensor. It should be noted that multiple integrated ultrasonic temperature sensors are used in this invention, with one sensor corresponding to each valve. The communication between the signal analysis module, the signal acquisition module, and the multiple integrated ultrasonic temperature sensors can be achieved using LoRa communication technology.

[0034] In this invention, "upstream and downstream of the valve" refers to the valves in the same group as the valve itself. Specifically, the internal leakage characteristic data of the upstream and downstream valves are collected using integrated ultrasonic temperature sensors configured on the upstream and downstream valves. In some other preferred embodiments, the ultrasonic temperature sensors can be installed on the pipes upstream and downstream of the valve, which can also collect the internal leakage characteristic data.

[0035] When a valve leaks internally, it generates jet turbulence in the downstream pipe, accompanied by noise. The acoustic frequency range is mainly concentrated between 15kHz and 50kHz, with the main interference source in industrial settings below 25kHz. Therefore, we need to identify the ultrasonic frequency range above 25kHz where the maximum noise generated during leakage occurs, conduct acoustic noise monitoring, and collect acoustic information from various valves under different pressures and pipe diameters to build a data model and determine the leakage status. Furthermore, since the gases and liquids flowing through pipelines and valves in industrial production processes are mostly at temperatures different from room temperature, there is a certain temperature difference. If a normally closed valve leaks, the upstream and downstream pipe temperatures are close; conversely, the upstream side is at operating temperature, and the downstream side is at room temperature.

[0036] Therefore, the internal leakage characteristic data in this invention includes acoustic data or temperature data. That is, it is possible to determine whether the valve has internal leakage based solely on acoustic data, or to combine acoustic data and temperature data to determine whether the valve has internal leakage.

[0037] In a preferred embodiment, acoustic data and temperature data are combined to determine whether the valve has internal leakage. First, the valve's internal leakage characteristic data are collected cyclically. Specifically, acoustic and temperature signals are acquired using an integrated ultrasonic temperature sensor. After amplification and filtering of the acoustic signal, it is input to the signal acquisition module along with the temperature signal. The signal processing module uses its built-in ADC to cyclically acquire the acoustic and temperature signals at a frequency of 5kHz.

[0038] Next, the leakage feature data is transformed to obtain leakage feature values. This transformation mainly targets acoustic data, converting it into coded values ​​ranging from 0 to 4096. The coded values ​​are then multiplied by a scaling factor of 0.05 to obtain the corresponding decibel values.

[0039] When both the decibel and temperature values ​​exceed the corresponding set thresholds, the system is deemed to have internal leakage characteristics. The ultrasonic temperature sensors upstream and downstream of the valve are then forcibly activated to collect internal leakage characteristic data. It should be noted that when comparing the internal leakage characteristic values ​​with the set thresholds, the comparison period can be extended. For example, if the decibel and temperature values ​​are less than or equal to the corresponding set thresholds for 10 consecutive seconds, it is considered a false alarm.

[0040] Please see Figure 3 Processing the upstream and downstream internal leakage characteristic data can yield the upstream and downstream internal leakage characteristic values. Comparing these values—specifically, the difference in decibel levels and temperature between the upstream and downstream valves—indicates internal leakage. If both the decibel and temperature values ​​exceed their respective threshold differences, the valve is considered to have internal leakage. If the differences in decibel and temperature values ​​are small, it may be due to other noise interference.

[0041] Finally, the leakage amount needs to be estimated based on the internal leakage characteristic values. Before this, a correlation between the internal leakage characteristic values ​​and the leakage amount needs to be established based on historical experience data or experimental simulation data, that is, each batch of bleach and temperature values ​​corresponds to a leakage amount. The correlation can be established by fitting curves or by artificial intelligence models.

[0042] Taking the establishment of a correlation between internal leakage characteristic value and leakage amount using a fitted curve as an example: obtain historical experience data or experimental simulation data, extract several data points from them, each data point including the decibel difference, temperature difference and corresponding leakage amount of the upstream and downstream when the valve leaks internally; use the decibel difference and temperature difference as independent variables and the leakage amount as dependent variable to perform curve fitting; then, substitute the real-time acquired characteristic difference into the acquired fitted curve to quickly estimate the leakage amount.

[0043] In a preferred embodiment, the valve's internal leakage is determined solely based on acoustic data. First, the decibel value corresponding to the valve is acquired. If the decibel value is greater than a decibel threshold, the valve is deemed to meet the characteristics of internal leakage. Next, the ultrasonic temperature sensors upstream and downstream of the valve are forcibly activated to collect the decibel values ​​from both sides. If the decibel difference between the upstream and downstream sides exceeds the corresponding difference threshold, the valve is determined to have internal leakage.

[0044] Different types and orifice diameters of valves exhibit significant differences in upstream and downstream values ​​during leakage, as shown in Tables 1 and 2. Therefore, it is necessary to set a difference threshold based on specific circumstances in order to more reasonably determine the internal leakage situation.

[0045] Table 1 Comparison of upstream and downstream values ​​during ball valve leakage.

[0046]

[0047] Table 2 Comparison of upstream and downstream values ​​during venting in pipelines with vent valves.

[0048]

[0049]

[0050] According to the experiment, when the gas pressure in the pipeline is constant, the larger the leak, the larger the value detected by the ultrasonic temperature sensor. Therefore, when the gas pressure in the pipeline is constant, the leakage amount can be estimated based on the value measured by the ultrasonic temperature sensor. Table 3 is a comparison table of acoustic values ​​and corresponding leakage amounts under a pressure of 400 kPa.

[0051] Table 3. Decibel Value-Leakage Amount Comparison Table

[0052] decibel (dB) <![CDATA[Leakage rate (m 3 / s)]]> 0 0 0.1-5.0 0.19 5.1-10.0 0.37 10.1-20.0 0.56 20.1-30.0 0.74 30.1-40.0 0.93 40.1-60.0 1.10 60.1-80.0 1.30 80.1-100.0 1.50 100.1-120.0 1.86

[0053] The aforementioned preset thresholds are set by those skilled in the art based on actual conditions or obtained through simulation using a large amount of data.

[0054] The working principle of this invention is as follows: Internal leakage characteristic data of the valve is collected cyclically; the internal leakage characteristic data is converted and processed to obtain internal leakage characteristic values; when the internal leakage characteristic value is greater than the internal leakage characteristic threshold, the internal leakage characteristic data of the valve upstream and downstream are forcibly collected. Simultaneously collecting the internal leakage characteristic data of the valve upstream and downstream, the difference between the corresponding internal leakage characteristic values ​​upstream and downstream is used to determine whether the valve has internal leakage; if yes, an early warning is issued, and the leakage amount is estimated based on the characteristic difference; otherwise, the valve is continuously monitored.

[0055] The above embodiments are only used to illustrate the technical methods of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of the present invention without departing from the spirit and scope of the technical methods of the present invention.

Claims

1. A method for detecting internal leakage in valves based on ultrasonic waves and temperature determination, characterized in that, include: Collect internal leakage characteristic data of valves in a loop; Transform and process the internal leakage feature data to obtain internal leakage feature values; When the internal leakage characteristic value is greater than the internal leakage characteristic threshold, the internal leakage characteristic data of the upstream and downstream of the valve will be forcibly collected; the internal leakage characteristic data includes acoustic data or temperature data. Simultaneously collect internal leakage characteristic data of the upstream and downstream of the valve, and determine whether the valve has internal leakage based on the characteristic difference between the corresponding internal leakage characteristic values ​​of the upstream and downstream of the valve; if yes, issue an early warning and estimate the leakage amount based on the characteristic difference; if no, continue to monitor the valve. The process of transforming the internal leakage feature data to obtain internal leakage feature values ​​includes: Extract acoustic and temperature data from the internal leakage feature data; The acoustic data is converted into corresponding encoded values, and the corresponding decibel values ​​are obtained by combining them with a scaling factor; and the temperature data is converted into temperature values. When the internal leakage characteristic value is greater than the internal leakage characteristic threshold, the upstream and downstream internal leakage characteristic data of the valve are forcibly collected, including: When both the decibel value and the temperature value exceed a certain threshold, the valve is determined to meet the leakage characteristics; the decibel and temperature thresholds are set empirically. The ultrasonic temperature integrated sensors upstream and downstream of the valve are forcibly activated to collect internal leakage characteristic data. The synchronous acquisition of internal leakage characteristic data of the upstream and downstream of the valve, and the determination of whether the valve has internal leakage based on the characteristic difference between the corresponding internal leakage characteristic values ​​of the upstream and downstream of the valve, includes: Extract decibel and temperature values ​​from the internal leakage characteristic values; Compare the decibel and temperature values ​​of the upstream and downstream valves to obtain the decibel difference and temperature difference; when both the decibel difference and temperature difference exceed the corresponding difference threshold, it is determined that the valve has internal leakage.

2. The method for detecting valve internal leakage based on ultrasonic waves and temperature as described in claim 1, characterized in that, The cyclically collected internal leakage characteristic data of the valve includes: Acoustic and temperature signals are acquired using an integrated ultrasonic temperature sensor; and the pre-processed acoustic and temperature signals are then input into the signal acquisition module. The signal acquisition module uses a built-in ADC to cyclically acquire acoustic and temperature signals to obtain internal leakage characteristic data; the cyclic acquisition frequency is 5kHz.

3. The method for detecting valve internal leakage based on ultrasonic waves and temperature as described in claim 2, characterized in that, The preprocessing of the acoustic signal includes amplification and filtering; and the filtering process removes acoustic signals other than those at a frequency of 40kHz.

4. The method for detecting valve internal leakage based on ultrasonic waves and temperature as described in claim 1, characterized in that, After determining that the valve has internal leakage, the leakage amount is estimated based on the characteristic difference, including: Extract decibel or temperature difference values ​​from the characteristic differences; The leakage amount is obtained by matching the decibel difference or temperature difference with the internal leakage characteristic value and the leakage amount correlation, and the early warning is given in combination with the leakage amount.

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