Combined valve pressure test device

Abstract

The invention provides a combined valve pressure test device, which comprises a hydraulic clamping module, a water pressure test module and a transportation track module, and is characterized in that the hydraulic clamping module and the water pressure test module are respectively arranged at two ends of the transportation track module and are connected into a whole through the transportation track module; the hydraulic clamping module comprises a pressure test table, a bottom plate, a supporting frame, a jack and a hydraulic pump, the water pressure test module comprises a water pressure pump, a water supply carbon steel pipeline, a pressure gauge and a ball valve, and the transportation track module comprises a track beam and a hoist group. The device comprises a pressure test table with complete tool clamps, a water pressure test module capable of boosting and reducing pressure, and a rail transportation module for assisting valve clamping and carrying. According to the invention, the pressure test work of two medium / large valves can be simultaneously and independently carried out, the carrying strength of personnel is reduced, the disassembly and assembly time of the valves is shortened, and the pressure test efficiency is greatly improved; in addition, the device further has an optimized lifting space, a pressure test water recycling and safety protection device can be additionally arranged, and the device is more environmentally friendly and safer.

Description

Technical Field

[0001] The invention relates to the technical field of valve pressure testing, and in particular to a combined valve pressure testing device. Background Art

[0002] Pipeline valve leakage accidents often occur in the petrochemical industry, and are often accompanied by irreversible accident hazards. The safety performance of valves used in the petrochemical industry is very important. The valve sealing, valve body strength and operational reliability at the construction site have always been the focus of attention of the owner, general contractor, supervisor and construction unit. Although, almost all valves used at construction sites have been pressure tested before leaving the factory, with corresponding test certificates and certificates. However, whether it is the owner, general contractor, or supervisor, they all require the construction site to conduct pressure tests to test the sealing and valve body strength of the valve. This process is also clearly written in the specifications, design instructions, and construction plans, which shows its importance.

[0003] In current construction sites, large valve pressure testing is usually not equipped with complete valve pressure testing equipment and valve handling facilities as in the valve manufacturer's production workshop. As a result, on-site valve pressure testing often requires greater labor and time costs. However, if you purchase the commonly used horizontal pressure testing device on the market, you will need to invest more money and transportation costs (expensive and difficult to transport), and once a failure occurs, the maintenance cycle will also have a significant impact on the project construction progress. Summary of the invention

[0004] In order to solve the above problems, the present invention discloses a combined valve pressure testing device, which can reduce the time cost, labor cost and capital cost in the construction process.

[0005] The specific plan is as follows:

[0006] A combined valve pressure test device, characterized in that it includes a hydraulic clamping module, a water pressure test module and a transport track module, wherein the hydraulic clamping module and the water pressure test module are respectively provided with a set at both ends of the transport track module and are connected into a whole by the transport track module; the hydraulic clamping module includes a pressure test platform, a base plate, a support frame, a jack and a hydraulic pump, the water pressure test module includes a water pressure pump, a water supply carbon steel pipeline, a pressure gauge and a ball valve, and the transport track module includes a track beam and a hoist group.

[0007] As a further improvement of the present invention, in the hydraulic clamping module, the base plate is arranged in the middle of the top surface of the pressure test bench, and a water inlet and outlet hole is provided in the middle. The supporting frame is a gantry frame fixed in the middle of the top surface of the pressure test bench. The jack is fixed at the middle bottom of the gantry frame and is connected to the hydraulic pump.

[0008] As a further improvement of the present invention, the pressure test platform is wide and flat, and the sizes of the left and right pressure test platforms are 200mm*1200mm and 1500mm*1500mm respectively. They are welded by HW350 steel, and the welds are color-detected; the bottom plate is a 35mm thick disc-shaped heavy steel plate, and the sizes of the left and right bottom plates are respectively and Center Open Inlet and outlet holes: concentric circles with a depth of 5 mm and a width of 15 mm are milled out every 100 mm on the upper surface of the bottom plate for installing sealing rings to increase the sealing effect; the support frame uses DN250 pipes as columns and welded to the pressure test table, HW250 steel as crossbeams, and a hole is opened in the middle The holes are connected with the bottom plate bolts of the jack; the left and right support frames are 1200mm and 1700mm high respectively. The 1200mm high support frame adds DN250 steel as a column above the beam to balance the height of the two support frames so as to install the track beam horizontally.

[0009] As a further improvement of the present invention, in the water pressure test module, the water pressure pump is connected to the water supply carbon steel pipeline, a pressure gauge and a ball valve are installed on the water supply carbon steel pipeline, and its water outlet end is connected to the inlet and outlet holes.

[0010] As a further improvement of the present invention, in the transport track module, the track beam frame is horizontally arranged, and its two ends are respectively fixedly mounted on the middle top of the two support frames, and the hoist group is slidably placed on the bottom of the track beam frame.

[0011] As a further improvement of the present invention, the assembly sequence is: prefabricate each module component, clean the bottom surface and mark the positioning, place the pressure test platform and the bottom plate, connect the water supply carbon steel pipeline and the pressure test pump, weld the support frame, install the jack and connect the hydraulic pump, install the track beam, and install the hoist group.

[0012] (1) The assembly location needs to be a flat cement floor with drainage measures.

[0013] (2) The pressure test platform should be stable and reliable. Washers can be used to level the platform to achieve horizontal installation requirements. After leveling, washers should be spot welded to the pressure test platform.

[0014] (3) After the base plate is placed on the pressure test bench, limit blocks need to be welded at the four corners.

[0015] (4) When connecting the column to the pressure test bench, welding or bolting can be used, but it requires adding ribs on both sides.

[0016] (5) Before installing the track beam, it is necessary to confirm that the top heights of the pressure test platforms on both sides are consistent to facilitate leveling of the track beam.

[0017] As a further improvement of the present invention, the method of use is as follows: the valve to be pressure tested is transported to the bottom of the track beam, and is moved to the pressure test platforms on both sides by a hoist group; polytetrafluoroethylene plates or wire clamping rubber pads are placed above and below the valve as sealing gaskets; a prefabricated pressure plate / pressure block is selected according to the size specifications of the pressure test valve, and is compressed using a hydraulic jack; a water pressure pump is started to perform sealing and strength tests; and according to the pressure test results, the pressure tested valve is disassembled and moved to a qualified area or an unqualified area.

[0018] As a further improvement of the present invention, the thickness of the pressing plate / pressing block is selected by a blind plate calculation formula, which is expressed as follows:

[0019]

[0020] Among them, δ is the blind plate thickness, mm; K is the condition coefficient, which is 0.4; D is the nominal diameter of the valve, mm; P is the test pressure, MPa; σ is the allowable stress, which is 113N / m2.

[0021] As a further improvement of the present invention, the through hole in the middle of the bottom plate is a bell-mouth, and a buffer tank is added at the bottom. The buffer tank is provided with a water inlet and a water outlet, wherein the water inlet is connected to a water pressure pump, and the water outlet is connected to a wastewater recovery pump and leads to a wastewater recovery system; the pressure test platform is a prefabricated fixed pressure plate of a single specification; a manual hoist group is added to the end of the track beam; baffles are added to the front and rear sides of the top surface of the pressure test platform.

[0022] The beneficial effects of the present invention are:

[0023] The present invention comprises a pressure test bench with complete fixtures, a pressure test module capable of boosting and reducing water pressure, and a rail transport module for assisting valve clamping and transportation; the present invention can independently perform pressure tests on two medium / large valves at the same time, which reduces the labor intensity of personnel transportation and the time for valve disassembly and assembly, greatly improving the pressure test efficiency; and the device also has an optimized lifting space, which can increase the pressure test water recovery and safety protection devices, and is more environmentally friendly and safe. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the device structure of the present invention.

[0025] Figure 2 It is a flow chart of the assembly sequence of the present invention.

[0026] Figure 3 The figure is a flow chart of the method for using the present invention.

[0027] Figure 4 This is a schematic diagram of Example 2.

[0028] Figure 5 This is a schematic diagram of Example 3.

[0029] Figure 6 This is a schematic diagram of Example 4.

[0030] Figure 7 This is a schematic diagram of Example 5.

[0031] List of reference numerals:

[0032] 1-pressure test bench, 2-base plate, 3-support frame, 4-jack, 5-hydraulic pump, 6-water pressure pump, 7-carbon steel water supply pipeline, 8-pressure gauge, 9-track beam, 10-hoist set. DETAILED DESCRIPTION

[0033] The present invention will be further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention.

[0034] Example 1

[0035] like Figure 1 As shown, the present application provides a combined valve pressure test device, including a hydraulic clamping module, a water pressure test module and a transport track module, wherein the hydraulic clamping module and the water pressure test module are respectively provided with a set at both ends of the transport track module, and are connected into a whole by the transport track module; the hydraulic clamping module includes a pressure test platform 1, a base plate 2, a support frame 3, a jack 4 and a hydraulic pump 5, the water pressure test module includes a water pressure pump 6, a water supply carbon steel pipeline 7, a pressure gauge 8 and a ball valve, and the transport track module includes a track beam 9 and a hoist group 10.

[0036] In this embodiment, in the hydraulic clamping module, the base plate is arranged in the middle of the top surface of the pressure test bench, and a water inlet and outlet hole is provided in the middle. The supporting frame is a gantry frame fixed in the middle of the top surface of the pressure test bench. The jack is fixed at the middle bottom of the gantry frame and is connected to the hydraulic pump.

[0037] In this embodiment, the pressure test platform is wide and flat, and the sizes of the left and right pressure test platforms are 200mm*1200mm and 1500mm*1500mm respectively. They are welded by HW350 steel, and the welds are color-detected; the bottom plate is a 35mm thick disc-shaped heavy steel plate, and the sizes of the left and right bottom plates are and Center Open Inlet and outlet holes: concentric circles with a depth of 5 mm and a width of 15 mm are milled out every 100 mm on the upper surface of the bottom plate for installing sealing rings to increase the sealing effect; the support frame uses DN250 pipes as columns and welded to the pressure test table, HW250 steel as crossbeams, and a hole is opened in the middle The holes are connected with the bottom plate bolts of the jack; the left and right support frames are 1200mm and 1700mm high respectively. The 1200mm high support frame adds DN250 steel as a column above the beam to balance the height of the two support frames so as to install the track beam horizontally.

[0038] In this embodiment, in the water pressure test module, the water pressure pump is connected to the water supply carbon steel pipeline, a pressure gauge and a ball valve are installed on the water supply carbon steel pipeline, and the water outlet end is connected to the inlet and outlet holes.

[0039] In this embodiment, in the transport track module, the track beam is horizontally arranged, and its two ends are respectively fixedly mounted on the middle top of two supporting frames, and the hoist group is slidably placed on the bottom of the track beam.

[0040] like Figure 2 As shown, the assembly sequence is: prefabricate each module component, clean the bottom surface and mark the position, place the pressure test platform and the bottom plate, connect the water supply carbon steel pipeline and the pressure test pump, weld the support frame, install the jack and connect the hydraulic pump, install the track beam, and install the hoist group.

[0041] (1) The assembly location needs to be a flat cement floor with drainage measures.

[0042] (2) The pressure test platform should be stable and reliable. Washers can be used to level the platform to achieve horizontal installation requirements. After leveling, washers should be spot welded to the pressure test platform.

[0043] (3) After the base plate is placed on the pressure test bench, limit blocks need to be welded at the four corners.

[0044] (4) When connecting the column to the pressure test bench, welding or bolting can be used, but it requires adding ribs on both sides.

[0045] (5) Before installing the track beam, it is necessary to confirm that the top heights of the pressure test platforms on both sides are consistent to facilitate leveling of the track beam.

[0046] like Figure 3 As shown, the method of use is: transport the valve that needs to be pressure tested to the bottom of the track beam, and use the hoist group to move it to the pressure test platform on both sides; place PTFE plates or wire clamping rubber pads on the upper and lower parts of the valve as sealing gaskets; select prefabricated pressure plates / pressure blocks according to the size specifications of the pressure test valve, and use hydraulic jacks to press them tightly; start the water pressure pump to perform sealing and strength tests; according to the pressure test results, disassemble the valve after the pressure test and move it to the qualified area or the unqualified area.

[0047] The thickness of the pressing plate / pressing block is selected by a blind plate calculation formula, and its expression is as follows:

[0048]

[0049] Among them, δ is the blind plate thickness, mm; K is the condition coefficient, which is 0.4; D is the nominal diameter of the valve, mm; P is the test pressure, MPa; σ is the allowable stress, which is 113N / m2.

[0050] Example 2

[0051] In this embodiment, it is considered that after each valve pressure test of the combined valve pressure test device, a lot of waste water will flow onto the surrounding ground and cannot be discharged into the drainage ditch in time. This often causes the ground of the pressure test site to be wet and dirty. There are usually a lot of electrical equipment in the pressure test site, so the wet ground not only easily causes the construction workers to slip, but also easily causes short circuit of electrical equipment and electric shock to people.

[0052] like Figure 4 As shown, in response to the above shortcomings, this article proposes to change the water inlet and outlet form of the pressure test bench. First, the water inlet under the bottom plate is optimized to a bell mouth, which is conducive to the backflow of the pressure test water after the pressure test. A pressure test water buffer tank should also be added under the bottom plate. The buffer tank is provided with two pipe openings, namely, a water inlet and a water outlet. The water inlet is connected to a water pressure pump, and the water outlet is connected to a wastewater recovery pump. The wastewater recovery system can add filtering facilities to achieve the effect of recycling. This improvement scheme makes the combined valve pressure test device safer and more environmentally friendly. The remaining technical features of this embodiment are the same as those of Example 1.

[0053] Example 3

[0054] In this embodiment, it is considered that when the combined valve pressure test device is used to test different valves, different pressure plates need to be selected and placed above the valves according to the valve size and test pressure. This solution requires prefabrication of pressure plates of various sizes and thicknesses, and each time the valve is replaced, it wastes time and manpower to carry them up and down. Large-sized pressure plates not only consume a lot of materials and are difficult to carry, but are also prone to dangers such as bumps and injuries.

[0055] like Figure 5 As shown, in order to address the above shortcomings, the pressure plates of various sizes and specifications on the pressure test platforms on both sides can be condensed into only one fixed pressure plate of a single specification prefabricated on both sides. The size and thickness of the single pressure plate must meet the pressure test requirements of the valve with the largest size and maximum test pressure in this project. During installation, the single fixed pressure plate is connected and fixed to the top of the jack, and the disassembly method of lifting and lowering by using a hydraulic system replaces manual handling. This improvement scheme can reduce the work of personnel disassembling and carrying the pressure plates, and at the same time, there is no need to spend energy on selecting different pressure plates. The remaining technical features of this embodiment are the same as those of Example 1.

[0056] Example 4

[0057] In this embodiment, considering that the current combined valve pressure test device adopts a single track and single lifting point method for transporting and hoisting valves, workers need to use auxiliary measures such as pushing, pulling and traction after transporting the valve to the pressure test platform to place the valve stably on the pressure test platform. This method not only reduces construction efficiency and increases labor intensity, but also easily causes bumps and damages to the valve.

[0058] like Figure 6 As shown, in response to the above shortcomings, an electric hoist group is selected as the main lifting equipment, and a manual hoist group is added at the end of the track beam as an auxiliary lifting device. Workers use electric hoists to transport the valve to the front of the pressure test bench, and then use manual hoists to pull the valve horizontally on the pressure test bench. The double lifting point solution can facilitate the placement of the valve, and the process from vertical state to horizontal placement can be smoothly transitioned. Therefore, this improved solution can be more efficient, reliable and safe, and reduce bumps and protect the valve sealing surface. The remaining technical features of this embodiment are the same as those of Example 1.

[0059] Example 5

[0060] In this embodiment, it is considered that no matter what type of valve pressure test device is used, during the valve pressure test, there may be a risk that the sealing gasket may be over-pressured or frequently used, causing the sealing gasket to rupture and splash, injuring the construction personnel. The pressure test platforms on both sides of the combined valve pressure test device are vertical pressure test platforms, and the sealing gasket splash direction of the vertical pressure test platform is horizontally radiated to all sides, so the injury area is extremely wide.

[0061] like Figure 7 As shown, in order to solve the above shortcomings, two baffles are set up at the column positions of the pressure test platform on both sides of the combined valve pressure test device (the baffle material can be made of wood or thin steel plate). When the high-pressure valve pressure test process is carried out, the pressure test construction personnel should hide behind the baffle to operate the water pressure pump. Adding a protective baffle can effectively prevent the sealing gasket from rupturing and splashing to injure the construction personnel, making the device safer. The remaining technical features of this embodiment are the same as those of Example 1.

[0062] The advantages of the present invention are:

[0063] (1) Low labor input: Using rails and hoists for transportation can reduce labor intensity and improve transportation efficiency. Only two workers are needed to complete the entire operation. And because the operation is simple, it also reduces the skill requirements for workers, and only general workers or laborers can perform the operation.

[0064] (2) Low time cost: Because the fixture is simple and convenient, it reduces the time for disassembly and installation of complex tooling. In addition, the pressure test tables on both sides can be used independently at the same time, which greatly improves the construction efficiency. The whole set of equipment can test 8 to 10 valves per hour on average.

[0065] (3) Wide range of applications: The combined valve pressure test device is applicable to various valve types including gate valves, stop valves, plug valves, check valves, floating ball valves, butterfly valves, fixed ball valves, etc. It also meets the maximum pressure test valve size of DN1200 and the maximum test pressure of 25Mpa. It can also increase the size of the base plate and pressure plate, and replace a higher-power hydraulic pump to achieve a wider range of applications.

[0066] The technical means disclosed in the scheme of the present invention are not limited to the technical means disclosed in the above-mentioned implementation mode, but also include technical schemes composed of any combination of the above-mentioned technical features. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications are also regarded as the protection scope of the present invention.

Claims

1. A combined valve pressure testing device, characterized in that: It includes a hydraulic clamping module, a water pressure test module and a transport track module. The hydraulic clamping module and the water pressure test module are respectively arranged in one set at both ends of the transport track module and are connected into a whole by the transport track module; the hydraulic clamping module includes a pressure test platform, a base plate, a support frame, a jack and a hydraulic pump; the water pressure test module includes a water pressure pump, a water supply carbon steel pipeline, a pressure gauge and a ball valve; the transport track module includes a track beam and a hoist group.

2. A combined valve pressure testing device according to claim 1, characterized in that: In the hydraulic clamping module, the bottom plate is arranged in the middle of the top surface of the pressure test bench, and a water inlet and outlet hole is provided in the middle. The supporting frame is a gantry frame fixed in the middle of the top surface of the pressure test bench. The jack is fixed in the middle bottom of the gantry frame and is connected to the hydraulic pump.

3. A combined valve pressure testing device according to claim 2, characterized in that: The pressure test platform is wide and flat, and the sizes of the left and right pressure test platforms are 200mm*1200mm and 1500mm*1500mm respectively. They are welded from HW350 steel, and the welds are color-detected. The bottom plate is a 35mm thick disc-shaped heavy steel plate. The dimensions of the left and right bottom plates are and Center Open For the inlet and outlet holes, concentric circles with a depth of 5 mm and a width of 15 mm are milled out every 100 mm on the upper surface of the bottom plate to install sealing rings to increase the sealing effect; The support frame uses DN250 pipes as columns and is welded to the pressure test platform, and HW250 steel is used as the crossbeam. The holes are connected with the bottom plate bolts of the jack; the left and right support frames are 1200mm and 1700mm high respectively. The 1200mm high support frame adds DN250 steel as a column above the beam to balance the height of the two support frames so as to install the track beam horizontally.

4. A combined valve pressure testing device according to claim 3, characterized in that: In the water pressure test module, the water pressure pump is connected to the water supply carbon steel pipeline, a pressure gauge and a ball valve are installed on the water supply carbon steel pipeline, and the water outlet end is connected to the inlet and outlet holes.

5. A combined valve pressure testing device according to claim 4, characterized in that: In the transport track module, the track beam frame is horizontally arranged, and its two ends are respectively fixedly mounted on the middle top of two supporting frames, and the hoist group is slidably placed on the bottom of the track beam frame.

6. A combined valve pressure testing device according to claim 5, characterized in that: The assembly sequence is: prefabricate each module component, clean the bottom surface and mark the positioning, place the pressure test bench and bottom plate, connect the water supply carbon steel pipe and the pressure test pump, weld the support frame, install the jack and connect the hydraulic pump, install the track beam, and install the hoist group.

7. A combined valve pressure testing device according to claim 6, characterized in that: The method of use is: transport the valve that needs to be pressure tested to the bottom of the track beam, and use the hoist group to move it to the pressure test platform on both sides; place PTFE plates or wire clamping rubber pads on the upper and lower parts of the valve as sealing gaskets; select prefabricated pressure plates / pressure blocks according to the size specifications of the pressure test valve, and use hydraulic jacks to tighten them; start the water pressure pump to perform sealing and strength tests; according to the pressure test results, disassemble the valve after the pressure test and move it to the qualified area or the unqualified area.

8. A combined valve pressure testing device according to claim 7, characterized in that: The thickness of the pressing plate / block is selected by a blind plate calculation formula, which is expressed as follows: Among them, δ is the blind plate thickness, mm; K is the condition coefficient, which is 0.4; D is the nominal diameter of the valve, mm; P is the test pressure, MPa; σ is the allowable stress, which is 113N / m2.

9. A combined valve pressure testing device according to claim 8, characterized in that: The through hole in the middle of the bottom plate is a bell-shaped mouth, and a buffer tank is added at the bottom. The buffer tank is provided with a water inlet and a water outlet, wherein the water inlet is connected to a water pressure pump, and the water outlet is connected to a wastewater recovery pump and leads to a wastewater recovery system; the pressure test platform is a prefabricated fixed pressure plate of a single specification; a manual hoist group is added to the end of the track beam; baffles are added to the front and rear sides of the top surface of the pressure test platform.

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