Multi-station simultaneous automatic verification device and method

Abstract

The invention discloses a multi-station simultaneous automatic verification device and method, and belongs to the technical field of safety valve verification, the multi-station simultaneous automatic verification device comprises a main air supply system, at least two branch air supply systems and at least two verification stations, and the main air supply system is provided with an air inlet valve and an emptying valve; each branch air supply system is provided with an air inlet valve, a flow control valve, a buffer tank, an emptying valve, a pressure sensor and a flow sensor. According to the invention, each verification station of the verification device adopts an independent air supply system and is independently controlled by an electromagnetic valve, so that independent verification of each verification station is realized without mutual interference, and the utilization rate of the device and the working efficiency of verification are improved; data collected in the verification process can be recorded and stored in real time through the industrial personal computer, and due to the fact that the multiple verification stations can conduct verification work at the same time, the verification stations are sufficient, each verification station can conduct repeated verification for multiple times, on one hand, errors can be eliminated, and on the other hand, the average value of the pressure collected for multiple times is taken as the setting pressure of the safety valve to be verified. And the accuracy of the verification result is ensured.

Description

Technical Field

[0001] The invention belongs to the technical field of safety valve calibration, and in particular relates to a multi-station simultaneous automatic calibration device and method. Background Art

[0002] Safety valves are installed on boilers, pressure vessels or other piping systems. They are valves that protect against overpressure. When the pressure exceeds the preset limit, the safety valve will automatically release the medium from the boiler, pressure vessel or other piping system to ensure that the system does not have an accident due to excessive pressure. Therefore, the performance of the safety valve determines the safety of the entire equipment or system. According to the relevant provisions of the "Safety Technical Supervision Regulations for Safety Valves", general safety valves need to be calibrated once a year.

[0003] At present, most of the safety valve calibration is mainly offline calibration, that is, the safety valve is removed from the equipment, and the calibration device simulates the actual use environment of the safety valve, installs the safety valve on the calibration bench, and gradually applies pressure to open the safety valve by providing air source pressure to its inlet, thereby verifying the accuracy of the safety valve opening pressure. Most of the existing calibration devices are mainly single-channel calibration, and the calibration station of the calibration bench is switched by the air source switching valve to realize the calibration of different valve calibers.

[0004] Since the calibration benches of existing calibration devices are basically single-channel, it is impossible to realize simultaneous calibration of multiple stations, resulting in low calibration efficiency. In particular, a sealing pressure test is required during the calibration process. At this time, the calibration personnel can only wait on site and cannot calibrate other safety valves at the same time. Although another calibration bench is equipped with multiple stations, due to its single-channel gas path, it cannot calibrate multiple safety valves at the same time, resulting in a waste of resources. Summary of the invention

[0005] The purpose of the present invention is to solve the problem that the existing calibration equipment has only a single-channel gas circuit and cannot realize simultaneous calibration of multiple stations, resulting in relatively low calibration efficiency, and to provide a multi-station simultaneous automatic calibration device and method.

[0006] In order to solve the above technical problems, the present invention provides a multi-station simultaneous automatic calibration device, comprising a main gas supply system for supplying gas to the safety valve to be calibrated, at least two branch gas supply systems connected to the main gas supply system, and at least two calibration stations;

[0007] The main gas supply system comprises a gas source and a main gas supply pipe, on which a main gas inlet valve and a main gas exhaust valve are arranged;

[0008] The branch air supply system includes a first air supply branch pipe, a buffer tank and a second air supply branch pipe. The air inlet end of the first air supply branch pipe is connected to the air supply main pipe. The first air supply branch pipe is provided with a branch electromagnetic air inlet valve and a branch flow control valve. The air outlet end of the first air supply branch pipe is connected to the air inlet of the buffer tank, and the air outlet of the buffer tank is connected to the second air supply branch pipe. The second air supply branch pipe is provided with a branch drain valve and a pressure sensor. The air outlet end of the second air supply branch pipe is installed on a calibration station. The calibration station is also provided with an air outlet pipe, and a flow sensor is provided on the air outlet pipe.

[0009] Preferably, the gas source is a high-pressure gas cylinder or a gas storage tank connected to an air compressor.

[0010] Furthermore, the main route air intake valve includes a main route manual air intake valve and a main route electromagnetic air intake valve, and the main route manual air intake valve is in a normally open state.

[0011] Furthermore, the main circuit drain valve includes a main circuit electromagnetic drain valve and a main circuit manual drain valve, the main circuit manual drain valve is connected in parallel with the main circuit electromagnetic drain valve, and the main circuit manual drain valve is in a normally closed state.

[0012] Furthermore, the branch drain valve includes a branch electromagnetic drain valve and a branch manual drain valve, the branch manual drain valve is connected in parallel with the branch electromagnetic drain valve, and the branch manual drain valve is in a normally closed state.

[0013] Preferably, there are two pressure sensors, and the accuracy and range of the two pressure sensors are consistent.

[0014] Furthermore, the device also includes a control system, which includes an industrial computer, and a data acquisition control unit is installed in the industrial computer. The data acquisition control unit is electrically connected to the main electromagnetic intake valve, the main electromagnetic exhaust valve, the branch electromagnetic intake valve, the branch flow control valve, the branch electromagnetic exhaust valve, the pressure sensor and the flow sensor respectively.

[0015] The multi-station simultaneous automatic calibration device of the present invention connects multiple branch air supply systems on the main air supply system. Each branch air supply system has its own air intake valve, flow control valve, buffer tank, drain valve, pressure sensor and flow sensor, so that each calibration station can be independently supplied with air and controlled. When a certain calibration station needs to be calibrated, the air intake and exhaust of the station can be controlled through the built-in data acquisition and control unit of the industrial computer, thereby meeting the needs of simultaneous calibration of multiple stations and calibrating multiple safety valves at the same time, thereby improving calibration efficiency.

[0016] In order to solve the above technical problems, the present invention also provides a method for simultaneous automatic calibration of multiple stations, using the above calibration device, and each calibration station is independently and automatically calibrated at the same time, and the calibration process of one calibration station includes the following steps:

[0017] (1) Air intake to the gas supply main: Open the main air intake valve to allow air to enter the gas supply main;

[0018] (2) Air intake into the air supply branch pipe: Open the branch air intake valve to allow air to enter the first air supply branch pipe and the second air supply branch pipe;

[0019] (3) Verification: Monitor the data of the pressure sensor and flow sensor in real time. When the pressure reaches 90% of the set pressure, control the flow controller to reduce the flow rate so that the pressure increase rate is reduced to <0.01MPa / s; open the safety valve to be verified and record the pressure value of the pressure sensor when the flow rate increases;

[0020] (4) Exhaust of gas supply branch pipes: close the branch air inlet valve, open the branch exhaust valve, and exhaust the gas in the first gas supply branch pipe and the second gas supply branch pipe;

[0021] (5) Repeat steps (2) to (4) at least three times and take the average of the pressure values ​​obtained during the multiple calibrations, which is the set pressure of the safety valve to be calibrated.

[0022] Furthermore, before verification, the safety valve to be verified needs to be fixed on one of the verification stations, and the second air supply branch pipe is connected to the inlet of the safety valve, and the air outlet pipe is connected to the outlet of the safety valve, and it is checked and ensured that the main line drain valve and the branch drain valve of the branch are in the closed state.

[0023] Furthermore, after the safety valves at all the calibration stations have been calibrated, it is necessary to close the main air inlet valve, open the main exhaust valve, and exhaust the gas in the main gas supply pipe for the next calibration.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] (1) Each calibration station adopts an independent air supply system, which is independently controlled by a solenoid valve to achieve independent calibration of each calibration station without interfering with each other, thus improving the utilization rate of the equipment and the efficiency of calibration;

[0026] (2) The entire calibration process can be automatically controlled and collected by the data acquisition control unit of the industrial computer, which avoids manual control, reduces manual work, and further improves work efficiency;

[0027] (3) The data collected during the calibration process at each calibration station can be recorded and saved in real time by the industrial computer. In addition, since multiple calibration stations can perform calibration work at the same time and there are sufficient calibration stations, each calibration station can repeat the calibration multiple times and compare the values ​​recorded multiple times. This can eliminate errors and take the average pressure as the set pressure of the safety valve to be calibrated, thus ensuring the accuracy of the calibration. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a structural schematic diagram of the multi-station simultaneous automatic calibration device of the present invention.

[0029] Legend:

[0030] 100-Main gas supply system; 110-Gas source; 120-Main gas supply pipe; 121-Main manual air inlet valve; 122-Main solenoid air inlet valve; 123-Main solenoid exhaust valve; 124-Main manual exhaust valve; 200-Branch gas supply system; 210-First gas supply branch pipe; 211-Branch solenoid air inlet valve; 212-Branch flow control valve; 220-Buffer tank; 230-Second gas supply branch pipe; 231-Branch solenoid exhaust valve; 232-Branch manual exhaust valve; 233-Pressure sensor; 300-Calibration station; 400-Air outlet pipe; 401-Flow sensor. DETAILED DESCRIPTION

[0031] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0032] This embodiment provides a multi-station simultaneous automatic verification device, such as Figure 1 As shown, it includes a main air supply system 100 for supplying air to the safety valve to be checked, a six-way branch air supply system 200 connected to the main air supply system 100, and six checking stations 300, which can simultaneously carry out the checking work of the six checking stations.

[0033] The main gas supply system 100 includes a gas source 110 and a gas supply main pipe 120. The gas source is a gas storage tank, which is connected to an air compressor. The gas supply main pipe 120 is provided with a main manual air intake valve 121, a main electromagnetic air intake valve 122, a main electromagnetic exhaust valve 123 and a main manual exhaust valve 124. The main manual exhaust valve 124 is connected in parallel with the main electromagnetic exhaust valve 123. The main manual air intake valve 121 is used as a backup valve for the main electromagnetic air intake valve 122 and is in a normally open state. When the main electromagnetic air intake valve 122 is closed, the main manual air intake valve 121 is closed. When the magnetic air inlet valve 122 fails or needs to be replaced, the main manual air inlet valve 121 can be manually closed to prevent leakage of gas in the gas tank; the main manual drain valve 124 is in a normally closed state. When the calibration work is completed, the main electromagnetic drain valve 124 can be manually opened while opening the main electromagnetic drain valve, or when the main electromagnetic drain valve 123 fails or needs to be replaced, the main manual drain valve 124 can be manually opened to drain the gas in the gas supply main pipe and eliminate the influence of residual gas in the pipeline on the next calibration work.

[0034] In the six-branch air supply system 200, each branch air supply system includes a first air supply branch pipe 210, a buffer tank 220, and a second air supply branch pipe 230. The air inlet end of the first air supply branch pipe 210 is connected to the air supply main pipe 120. The first air supply branch pipe 210 is provided with a branch electromagnetic air inlet valve 211 and a branch flow control valve 212. The branch electromagnetic air inlet valve 211 is used to control the air inlet of each branch air supply system. The branch flow control valve 212 plays the role of regulating and controlling the flow. When the pressure exceeds 90% of the set pressure of the safety valve, the pressure rise speed is controlled. The rate does not exceed 0.01MPa / s; the outlet end of the first air supply branch pipe 210 is connected to the air inlet of the buffer tank 220, and the buffer tank 220 plays the role of buffering the air source pressure to ensure the stability of the pressure in the second air supply branch pipe 230. The air outlet of the buffer tank 220 is connected to the second air supply branch pipe 230. The second air supply branch pipe 230 is provided with a branch electromagnetic drain valve 231, a branch manual drain valve 232 and a pressure sensor 233. The branch electromagnetic drain valve 231 is connected in parallel with the branch manual drain valve 232, and the branch manual drain valve 232 is normally closed. When the branch electromagnetic drain valve 231 fails, the branch gas supply system can be exhausted through the branch manual drain valve 232. There are two pressure sensors 233. The accuracy and range of the two pressure sensors 233 are consistent, and the automatic mutual inspection function is performed. When the pressures detected by the two pressure sensors 233 are inconsistent, the control system can automatically identify that the pressure sensor 233 has failed, and it is necessary to stop the work for maintenance or replace the failed pressure sensor 233 to ensure the accuracy of the calibration; the outlet end of the second gas supply branch pipe 230 is installed at the calibration station 300 During verification, the outlet end of the second gas supply branch pipe 230 must be connected to the inlet of the safety valve to be verified; the verification station 300 is also provided with an outlet pipe 400, and a flow sensor 401 is provided on the outlet pipe 400. During verification, the outlet pipe 400 must be connected to the outlet of the safety valve to be verified. The flow sensor 401 is used to monitor the gas flow in the outlet pipe 400 during the entire verification process. When the safety valve is opened, there will be an abnormal increase in the flow rate, so as to automatically determine the opening of the safety valve, and the pressure value recorded at this moment is the set pressure of the safety valve.

[0035] As a preferred embodiment of the present invention, it also includes a control system 500, which includes an industrial computer 501, which is preferably an industrial computer. The industrial computer 501 is equipped with a data acquisition control unit 502, which is electrically connected to the main electromagnetic air intake valve 122 and the main electromagnetic exhaust valve 123 of the main air supply system 100, the branch electromagnetic air intake valve 211, the branch flow control valve 212, the branch electromagnetic exhaust valve 231, the pressure sensor 233 of each branch air supply system 200, and the flow sensor 401 of the air outlet pipe 400, and is used for the control of the main electromagnetic air intake valve 211, the main electromagnetic exhaust valve 212, and each branch electromagnetic air intake valve 211, the branch flow control valve 212, the branch electromagnetic exhaust valve 231 and the signal acquisition of the pressure sensor 233 and the flow sensor 401, so as to realize the automatic control of each calibration station.

[0036] This embodiment also provides a multi-station simultaneous automatic calibration method, which realizes simultaneous independent automatic calibration of multiple calibration stations, and specifically includes the following steps:

[0037] S1. Preparation before calibration: Before calibration, fix the safety valve to be calibrated on the calibration station, check and ensure that the main circuit electromagnetic drain valve, the main circuit manual drain valve and the branch electromagnetic drain valve and branch manual drain valve of each branch are all in the closed state;

[0038] S2, multi-station simultaneous calibration, including:

[0039] S21, the industrial computer controls the opening of the main electromagnetic air inlet valve to supply air to the main air supply pipe;

[0040] S22, opening the branch electromagnetic air inlet valves of the branch air supply systems corresponding to all the stations to be inspected, and supplying air to all the first air supply branches and the second air supply branches connected to the stations to be inspected;

[0041] S23, real-time monitoring of the data of each pressure sensor and flow sensor, when the pressure reaches 90% of the set pressure of the safety valve to be calibrated, control the flow controller to reduce the flow rate so that the pressure increase rate is reduced to <0.01MPa / s; open the safety valve to be calibrated, and record the pressure value of the pressure sensor when the flow rate suddenly increases;

[0042] S24, closing the branch electromagnetic air inlet valve of the branch air supply system that has been verified, opening the branch electromagnetic exhaust valve, and exhausting the gas in the first air supply branch pipe and the second air supply branch pipe;

[0043] S25. Repeat the operations of S22 to S24 at least 3 times, and take the average of the pressure values ​​of multiple calibrations, which is the set pressure of the safety valve to be calibrated;

[0044] S3. After all calibration stations are calibrated, close the main electromagnetic air inlet valve, open the main electromagnetic exhaust valve, and exhaust the gas in the main gas supply pipe for the next calibration.

[0045] In the multi-station simultaneous automatic calibration method of the present invention, the data collected during the calibration process of each calibration station are recorded and saved in real time by the industrial control computer. Moreover, since multiple calibration stations can perform calibration work at the same time and there are sufficient calibration stations, each calibration station can repeat the calibration at least 3 times, and the values ​​recorded three times can be compared. Firstly, errors can be eliminated, and secondly, the average value of the pressure can be taken as the set pressure of the safety valve to be calibrated, thereby ensuring the accuracy of the calibration.

[0046] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. A person skilled in the art should understand that the technical solutions described in the above embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the protection scope of the present invention.

Claims

1. A multi-station simultaneous automatic calibration device, characterized in that: It comprises a main gas supply system (100) for supplying gas to the safety valve to be checked, at least two branch gas supply systems (200) connected to the main gas supply system (100), and at least two checking stations (300); The main gas supply system (100) comprises a gas source (110) and a main gas supply pipe (120), and the main gas supply pipe (120) is provided with a main gas inlet valve and a main gas exhaust valve; The branch air supply system (200) comprises a first air supply branch pipe (210), a buffer tank (220) and a second air supply branch pipe (230); the air inlet end of the first air supply branch pipe (210) is connected to the air supply main pipe (120); a branch electromagnetic air inlet valve (211) and a branch flow control valve (212) are arranged on the first air supply branch pipe (210); the air outlet end of the first air supply branch pipe (210) is connected to the air inlet of the buffer tank (220); the air outlet of the buffer tank (220) is connected to the second air supply branch pipe (230); a branch drain valve and a pressure sensor (233) are arranged on the second air supply branch pipe (230); the air outlet end of the second air supply branch pipe (230) is installed on the calibration station (300); the calibration station (300) is also provided with an air outlet pipe (400); and a flow sensor (401) is arranged on the air outlet pipe (400).

2. The multi-station simultaneous automatic inspection device according to claim 1, characterized in that: The gas source (110) is a high-pressure gas cylinder or a gas storage tank connected to an air compressor.

3. The multi-station simultaneous automatic inspection device according to claim 1 or 2, characterized in that: The main route air intake valve comprises a main route manual air intake valve (121) and a main route electromagnetic air intake valve (122), and the main route manual air intake valve (121) is in a normally open state.

4. The multi-station simultaneous automatic inspection device according to claim 3, characterized in that: The main circuit drain valve comprises a main circuit electromagnetic drain valve (123) and a main circuit manual drain valve (124). The main circuit manual drain valve (124) is connected in parallel with the main circuit electromagnetic drain valve (123). The main circuit manual drain valve (124) is in a normally closed state.

5. The multi-station simultaneous automatic inspection device according to claim 4, characterized in that: The branch drain valve comprises a branch electromagnetic drain valve (231) and a branch manual drain valve (232). The branch manual drain valve (232) is connected in parallel with the branch electromagnetic drain valve (231). The branch manual drain valve (232) is in a normally closed state.

6. The multi-station simultaneous automatic inspection device according to claim 1 or 5, characterized in that: The number of the pressure sensors (233) is two, and the accuracy and measuring range of the two pressure sensors (233) are consistent.

7. The multi-station simultaneous automatic inspection device according to claim 5, characterized in that: The device further comprises a control system (500), wherein the control system (500) comprises an industrial computer (501), wherein the industrial computer (501) is provided with a data acquisition control unit (502), and wherein the data acquisition control unit (502) is respectively electrically connected to a main electromagnetic air intake valve (122), a main electromagnetic exhaust valve (123), a branch electromagnetic air intake valve (211), a branch flow control valve (212), a branch electromagnetic exhaust valve (231), a pressure sensor (233), and a flow sensor (401).

8. A multi-station simultaneous automatic calibration method, characterized in that: The calibration device according to any one of claims 1 to 7 is used, and each calibration station is independently and automatically calibrated, and the calibration process of one calibration station includes the following steps: (1) Air intake to the gas supply main: Open the main air intake valve to allow air to enter the gas supply main; (2) Air intake into the air supply branch pipe: Open the branch air intake valve to allow air to enter the first air supply branch pipe and the second air supply branch pipe; (3) Verification: Monitor the data of the pressure sensor and flow sensor in real time. When the pressure reaches 90% of the set pressure, control the flow controller to reduce the flow rate so that the pressure increase rate is reduced to <0.01MPa / s; open the safety valve to be verified and record the pressure value of the pressure sensor when the flow rate increases; (4) Exhaust of gas supply branch pipes: close the branch air inlet valve, open the branch exhaust valve, and exhaust the gas in the first gas supply branch pipe and the second gas supply branch pipe; (5) Repeat steps (2) to (4) at least three times and take the average of the pressure values ​​obtained during the multiple calibrations, which is the set pressure of the safety valve to be calibrated.

9. The multi-station simultaneous automatic verification method according to claim 8, characterized in that: It also includes the preparation process before calibration: fix the safety valve to be calibrated on one of the calibration stations, connect the second air supply branch pipe to the inlet of the safety valve, connect the air outlet pipe to the outlet of the safety valve, check and ensure that the main drain valve and branch drain valve are in the closed state.

10. The multi-station simultaneous automatic verification method according to claim 8 or 9, characterized in that: It also includes the exhaust process after all the calibration stations are calibrated: close the main air inlet valve, open the main exhaust valve, and exhaust the gas in the main gas supply pipe.

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