Level gage device with leakage self-diagnosis function and monitoring method

Abstract

According to the level gage device with the leakage self-diagnosis function and the monitoring method, when the level gage device is used for a high-pressure tank body, if the level gage is damaged due to a certain reason, a leakage monitoring assembly at the rear end of the level gage can prevent materials and high-pressure gas in the tank body from leaking out of the tank body, and meanwhile an alarm signal can be sent out in real time; the material level indicator device can be isolated from the rear end through the pressure bearing cavity and the leakage monitoring assembly, pressure and materials are prevented from leaking out of the tank body, continuous production is not affected, and the safety performance is greatly improved.

Description

Technical Field

[0001] The invention relates to a material level meter device with leakage self-diagnosis function and a monitoring method, belonging to the field of material level monitoring technology design. Background Art

[0002] In industrial production and manufacturing processes, it is often necessary to monitor the position of solid particles or liquids such as coal powder, flour, grain, plastic particles, detergents, etc. in order to control the industrial production process.

[0003] Some storage tanks have a high-pressure environment inside. During the use of the level meter, the level meter body or its extension rod may be damaged due to material level impact, friction, high temperature, high pressure, etc., so that the pressure leaks out of the tank along the hollow part of the level meter or its extension rod, affecting normal production and causing serious safety accidents. Summary of the invention

[0004] The technical problem solved by the present invention is: in view of the problem that the existing material level meter in the current prior art does not have a leakage self-diagnosis function, which causes leakage of materials and high-pressure gas in the tank when damaged, thereby causing production accidents, a material level meter device and a monitoring method with a leakage self-diagnosis function are proposed.

[0005] The present invention solves the above technical problems by the following technical solutions:

[0006] A material level meter device with a leakage self-diagnosis function includes a material level meter probe, an extension rod, a mounting flange, a material level meter cable, a pressure interface, a leakage monitoring component, and a transmitter, wherein:

[0007] One end of the extension rod passes through the center hole of the mounting flange, and the other end is welded with a level meter probe to monitor the material; a pressure interface is provided on the side of the extension rod passing through the center hole of the flange, which is used to monitor the sealing performance and pressure resistance of the level meter; the leakage monitoring component is connected to the end of the extension rod passing through the center hole of the flange to monitor the pressure of the level meter, and the leakage monitoring component is inserted into the extension rod through the level meter cable and connected to the level meter probe; the transmitter is screwed on the outside of the leakage monitoring component to perform signal processing on the material signal and pressure signal collected by the leakage monitoring component.

[0008] The connection position of the mounting flange and the extension rod, the setting position of the pressure interface, and the setting position of the leakage monitoring component are all connected by welding. The leakage monitoring component is screwed and fixed in the transmitter. The level meter is divided into a pressure chamber and a transmitter chamber based on the installation position of the leakage monitoring component. When measuring the material in the tank, the pressure chamber extends into the tank to collect material signals.

[0009] The pressure interface includes a bell mouth, a jacket nut, and a plug, wherein:

[0010] One end of the bell mouth is welded to the extension rod, and the other end is provided with an external thread. The plug is fixed to the bell mouth through a sleeve nut. A preset pressure is applied to the pressure-bearing cavity through the bell mouth to detect the sealing performance and pressure resistance of the level meter.

[0011] The leakage monitoring assembly includes a transition joint, an electrical penetration, a side sealing O-ring, a fastening nut, a pressure sensor, and an end face sealing O-ring, wherein:

[0012] The lower end of the transition joint is welded and fixed to the lower end of the extension rod and the end of the extension rod, the upper end of the transition joint is connected to the transmitter through an external thread, the connection surface is sealed by an end face O-ring, and a mounting end face for installing an electrical penetration and an internal thread for fastening the electrical penetration are provided in the transition joint; the electrical penetration is fastened to the transition joint by a fastening nut, and is fixedly connected to the transition joint through the mounting end face and the internal thread, and the sealing is ensured by the end face sealing O-ring and the side sealing O-ring.

[0013] The electrical penetration piece comprises a penetration piece body, a ceramic isolation layer and a pin, wherein:

[0014] The ceramic isolation layer is arranged between the penetration body and the pin, and is connected and fixed with the penetration body and the pin through a sintering process to achieve insulation and sealing; a connecting thread and a sealing surface for connecting the pressure sensor are arranged at the center of the penetration body, and a sealing ring groove and a sealing end surface are arranged on the outside of the penetration body for sealing, and the penetration body is sealed and connected to the transition joint through a fastening nut.

[0015] The pressure sensor comprises a sensor body, a sensor sealing ring, a sensor output lead, and a sensor threaded joint, wherein:

[0016] A threaded joint is provided at the bottom of the sensor body, and the sensor body is fastened to the electrical penetration piece through the threaded joint, and the sealing is ensured by the sensor sealing ring between the connection surfaces; the pressure sensor is connected to the transmitter through the sensor output lead to transmit the pressure signal.

[0017] The level meter cable includes a signal line and a socket. The signal line is inserted into the extension rod and plugged into the pin of the electrical penetration piece through the socket on the outer side of the leakage monitoring component. The other end of the pin is led out through the socket on the other side of the leakage monitoring component and connected to the transmitter.

[0018] A material level monitoring method implemented according to a material level meter device comprises:

[0019] The material level meter probe and extension rod extend into the tank to monitor the material level and generate material signals. The pressure sensor monitors the pressure of the pressure chamber in real time and generates pressure signals.

[0020] Use the level meter cable to transmit material signals and pressure signals to the leakage monitoring component and transmitter, determine the material situation in the tank based on the material signal, and determine whether the level meter needs pressure relief control based on the pressure signal;

[0021] If the pressure value of the pressure signal is greater than the pressure threshold of the level meter, an alarm signal is generated, and the pressure interface is opened for pressure relief according to the alarm signal; otherwise, the level meter works normally.

[0022] After the pressure is relieved through the pressure interface, the level meter is externally sealed through the end face sealing O-ring of the leakage monitoring component to ensure that the tank pressure will not leak to the outside.

[0023] The advantages of the present invention compared with the prior art are:

[0024] (1) The present invention provides a material level meter device and monitoring method with a leakage self-diagnosis function, which solves the problem of pressure and material leakage in the storage tank caused by damage to the material level meter. In the case where the material level meter is damaged and pressure enters the pressure chamber, an alarm signal can be generated and an alarm can be notified in real time to the central control room to take corresponding measures. At the same time, the pressure chamber is isolated from the back end through a leakage monitoring component, which prevents pressure and material from leaking out of the tank body without affecting continued production, greatly improving safety performance;

[0025] (2) The level meter device provided by the present invention has a stable overall structure, can transmit signals through cable design, and can detect the pressure of the level meter itself while monitoring the material in the tank. The transmitter is used to realize signal transmission, and the leakage monitoring component is used to realize the partition design of the level meter. While monitoring the material, safety measures are paid attention to. The overall structure is stable and the signal measurement accuracy is high. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A schematic diagram of a material level meter provided by the present invention;

[0027] Figure 2 A schematic diagram of the pressure interface provided by the present invention;

[0028] Figure 3 A schematic diagram of a plug provided by the present invention;

[0029] Figure 4 A schematic diagram of a leakage monitoring assembly provided by the present invention;

[0030] Figure 5 A schematic diagram of an electrical penetration provided by the present invention;

[0031] Figure 6 A schematic diagram of a pressure sensor provided by the present invention;

[0032] Figure 7This is an assembly diagram of the electrical penetration piece and the pressure sensor provided by the present invention. DETAILED DESCRIPTION

[0033] A material level meter device and monitoring method with a leakage self-diagnosis function. When used in a high-pressure tank, if the material level meter is damaged due to some reason, the leakage monitoring component at the rear end of the material level meter can prevent the material and high-pressure gas in the tank from leaking out of the tank, and can also send out an alarm signal in real time to notify the central control room to take relevant measures to avoid further accidents. The material level meter device can be isolated from the rear end through the pressure chamber through the leakage monitoring component, preventing the pressure and material from leaking out of the tank, without affecting continued production, and greatly improving safety performance.

[0034] A material level meter device with a leakage self-diagnosis function comprises:

[0035] It includes a level meter probe, an extension rod, a mounting flange, a level meter cable, a pressure interface, a leakage monitoring component, and a transmitter, including:

[0036] One end of the extension rod passes through the center hole of the mounting flange, and the other end is welded with a level meter probe to monitor the material; a pressure interface is provided on the side where the extension rod passes through the center hole of the flange, which is used to monitor the sealing performance and pressure resistance of the level meter; the leakage monitoring component is provided at the end position of the extension rod on the side where the extension rod passes through the center hole of the mounting flange, which is used to monitor the pressure condition of the level meter, and the transmitter is screwed on the outside of the leakage monitoring component to perform signal processing on the material signal and pressure signal collected by the leakage monitoring component.

[0037] The connection position between the mounting flange and the extension rod, the setting position of the pressure interface, and the setting position of the leakage monitoring component are all connected by welding. The leakage monitoring component is screwed and fixed in the transmitter, and is connected to the level meter probe through the level meter cable; the level meter cable passes through the extension rod to connect the leakage monitoring component and the level meter probe; the level meter is divided into a pressure chamber and a transmitter chamber based on the installation position of the leakage monitoring component. When measuring the material in the tank, the pressure chamber extends into the tank to collect material signals.

[0038] The pressure interface includes a bell mouth, a jacket nut, and a plug, among which:

[0039] One end of the bell mouth is welded to the extension rod, and the other end is provided with an external thread. The plug is fixed to the bell mouth through a sleeve nut. A preset pressure is applied to the pressure-bearing cavity through the bell mouth to detect the sealing performance and pressure resistance of the level meter.

[0040] The leakage monitoring assembly includes a transition joint, an electrical penetration, a side sealing O-ring, a fastening nut, a pressure sensor, and an end face sealing O-ring, among which:

[0041] The lower end of the transition joint is welded and fixed to the lower end of the extension rod and the end of the extension rod, the upper end of the transition joint is connected to the transmitter through an external thread, the connection surface is sealed by an end face O-ring, and a mounting end face for installing an electrical penetration and an internal thread for fastening the electrical penetration are provided in the transition joint; the electrical penetration is fastened to the transition joint by a fastening nut, and is fixedly connected to the transition joint through the mounting end face and the internal thread, and the sealing is ensured by the end face sealing O-ring and the side sealing O-ring.

[0042] The electrical penetration includes a penetration body, a ceramic isolation layer and a pin, wherein:

[0043] The ceramic isolation layer is arranged between the penetration body and the pin, and is connected and fixed with the penetration body and the pin through a sintering process to achieve insulation and sealing; a connecting thread and a sealing surface for connecting the pressure sensor are arranged at the center of the penetration body, and a sealing ring groove and a sealing end surface are arranged on the outside of the penetration body for sealing, and the penetration body is sealed and connected to the transition joint through a fastening nut.

[0044] The pressure sensor includes a sensor body, a sensor sealing ring, a sensor output lead, and a sensor threaded joint, wherein:

[0045] A threaded joint is provided at the bottom of the sensor body, and the sensor body is fastened to the electrical penetration piece through the threaded joint, and the sealing is ensured by the sensor sealing ring between the connection surfaces; the pressure sensor is connected to the transmitter through the sensor output lead to transmit the pressure signal.

[0046] The level meter cable includes a signal line and a socket. The signal line is inserted into the extension rod and plugged into the pin of the electrical penetration piece through the socket on the outer side of the leakage monitoring component. The other end of the pin is led out through the socket on the other side of the leakage monitoring component and connected to the transmitter.

[0047] The material monitoring method of the material level meter device is specifically as follows:

[0048] The material level meter probe and extension rod extend into the tank to monitor the material level and generate material signals. The pressure sensor monitors the pressure of the pressure chamber in real time and generates pressure signals.

[0049] Use the level meter cable to transmit material signals and pressure signals to the leakage monitoring component and transmitter, determine the material situation in the tank based on the material signal, and determine whether the level meter needs pressure relief control based on the pressure signal;

[0050] If the pressure value of the pressure signal is greater than the pressure threshold of the level meter, an alarm signal is generated, and the pressure interface is opened for pressure relief according to the alarm signal; otherwise, the level meter works normally.

[0051] After the pressure is relieved through the pressure interface, the level meter is externally sealed through the end face sealing O-ring of the leakage monitoring component to ensure that the tank pressure will not leak to the outside.

[0052] The following is further described in conjunction with the accompanying drawings and preferred embodiments of the specification:

[0053] In the current embodiment, the material level meter structure is as follows Figure 1 As shown, it includes a level meter probe 1, an extension rod 2, a mounting flange 3, a level meter cable 4, a pressure interface 5, a leakage monitoring component 6, and a transmitter 7;

[0054] The level meter probe 1 is welded to the end of the extension rod 2. The extension rod 2 passes through the center hole of the mounting flange 3 and is welded at the junction of the front and back sides of the mounting flange 3 and the extension rod 2 to ensure the welding strength. A pressure interface 5 is welded near the upper end surface of the extension rod 2. The pressure interface 5 includes a 37° bell mouth 51, a jacket nut 52 and a plug 53, such as Figure 2 , Figure 3 As shown. One end of the 37° bell mouth 51 is welded to the extension rod, and the other end has an external thread; the plug 53 is fixed to the 37° bell mouth 51 through the outer sleeve nut 52. Its function is to apply a specified pressure to the inside of the level meter through the 37° bell mouth 51 and maintain it for a certain period of time after the level meter is produced, so as to detect whether the sealing performance and pressure resistance strength of the level meter are in compliance. After the test is completed, the pressure is released and the interface is sealed with the plug 53.

[0055] The upper end of the extension rod 2 is welded to the leakage monitoring assembly 6, which includes a transition joint 61, an electrical penetration 62, a sealing O-ring 63, a fastening nut 64, a pressure sensor 65, and a sealing O-ring 66. Figure 4 The lower end of the transition joint 61 is welded to the extension rod 2, and the upper end is connected to the transmitter housing through threads, and the connection surface is sealed with an O-ring 66. The transition joint 61 is processed with an end face for installing the electrical penetration 62 and an internal thread for fastening the electrical penetration.

[0056] The electrical penetration piece 62 is composed of a penetration piece body 622, a ceramic isolation layer 626 and a pin 621. The ceramic isolation layer 626 is located between the penetration piece body 622 and the pin 621. Through the sintering process, the ceramic isolation layer 626 grows closely together with the penetration piece body 622 and the pin 621, thereby playing the role of sealing and resisting high pressure and insulating each other. It can withstand a high pressure of 10MPa. The number of pins is determined by actual use requirements, such as Figure 5As shown in the figure, there are connecting threads 623 and sealing surfaces 625 for connecting pressure sensor 65 in the center of penetration body 622; there are sealing ring grooves and sealing end surfaces 624 on the outside of penetration body 622. Electrical penetration 62 is fastened to transition joint 61 by fastening nut 64; and the transition joint 61 is sealed by an end face sealing O-ring and a side sealing O-ring 63.

[0057] The pressure sensor 65 includes a sensor body 653, a sensor sealing ring 652, a sensor output lead 654, and a sensor threaded connector 651. Figure 6 The bottom threaded joint 651 is fastened to the electrical penetration 62; the connection surfaces are sealed by an end face sealing O-ring and a side sealing O-ring 652, as shown. Figure 7 As shown; the sensor signal is transmitted to the transmitter 7 for processing via the output lead 654.

[0058] The leakage monitoring assembly 6 is connected to the transmitter housing 7 through a thread 67, and the connection end face is sealed by an O-ring 66. The leakage monitoring assembly 6 separates the level meter into two upper and lower cavities, namely, a lower pressure-bearing cavity and an upper transmitter housing cavity.

[0059] The level meter cable 4 passes through the extension rod 2, wherein the signal line 41 is plugged into the pin 621 of the electrical penetration 62 in the leakage monitoring component 6 through the socket 42; the level meter cable is also led out through the socket at the other end corresponding to the electrical penetration pin 621; and is connected to the transmitter 7, which processes the signal, thereby realizing electrical transmission and anti-leakage high-voltage isolation.

[0060] The working process and leakage monitoring principle of the level meter are as follows: when working normally, the level meter monitors the material level in the tank in real time and outputs the material level signal; the pressure sensor monitors the pressure in the lower pressure chamber of the level meter in real time. When working normally, the pressure in the lower pressure chamber is one atmospheric pressure; if the level meter is damaged, the high pressure in the storage tank enters the pressure chamber, causing the pressure therein to exceed the set threshold; the pressure sensor detects this change and outputs an alarm signal to notify the central control room of a pressure leak and take relevant measures. At the same time, due to the sealing effect of the leakage monitoring component, the tank pressure will not leak into the external environment, and the entire system can continue to work without causing safety accidents.

[0061] In this embodiment, a level meter with a leakage self-diagnosis function is used to solve the problem of pressure and material leakage in the storage tank caused by damage to the level meter. Once the level meter is damaged and pressure enters the pressure chamber, a real-time alarm is issued to notify the central control room to take corresponding measures. At the same time, the pressure chamber is isolated from the back end through the leakage monitoring component, preventing pressure and material from leaking out of the tank, without affecting continued production, greatly improving safety performance.

[0062] Although the present invention has been disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications to the technical solution of the present invention by using the methods and technical contents disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope of the technical solution of the present invention.

[0063] The contents not described in detail in the specification of the present invention belong to the common knowledge of those skilled in the art.

Claims

1. A material level meter device with leakage self-diagnosis function, characterized in that: It includes a level meter probe, an extension rod, a mounting flange, a level meter cable, a pressure interface, a leakage monitoring component, and a transmitter, including: One end of the extension rod passes through the center hole of the mounting flange, and the other end is welded with a level meter probe to monitor the material; a pressure interface is provided on the side where the extension rod passes through the center hole of the flange, which is used to monitor the sealing performance and pressure resistance of the level meter; the leakage monitoring component is provided at the end position of the extension rod on the side where the extension rod passes through the center hole of the mounting flange, which is used to monitor the pressure condition of the level meter, and the transmitter is screwed on the outside of the leakage monitoring component to perform signal processing on the material signal and pressure signal collected by the leakage monitoring component.

2. A material level meter device with leakage self-diagnosis function according to claim 1, characterized in that: The connection position of the mounting flange and the extension rod, the setting position of the pressure interface, and the setting position of the leakage monitoring component are all connected by welding. The leakage monitoring component is screwed and fixed in the transmitter, and is connected to the level meter probe through the level meter cable; the level meter cable passes through the extension rod to connect the leakage monitoring component and the level meter probe; the level meter is divided into a pressure chamber and a transmitter chamber based on the installation position of the leakage monitoring component. When measuring the material in the tank, the pressure chamber extends into the tank to collect material signals.

3. A material level meter device with leakage self-diagnosis function according to claim 2, characterized in that: The pressure interface includes a bell mouth, a jacket nut, and a plug, wherein: One end of the bell mouth is welded to the extension rod, and the other end is provided with an external thread. The plug is fixed to the bell mouth through a sleeve nut. A preset pressure is applied to the pressure-bearing cavity through the bell mouth to detect the sealing performance and pressure resistance of the level meter.

4. A material level meter device with leakage self-diagnosis function according to claim 2, characterized in that: The leakage monitoring assembly includes a transition joint, an electrical penetration, a side sealing O-ring, a fastening nut, a pressure sensor, and an end face sealing O-ring, wherein: The lower end of the transition joint is welded and fixed to the lower end of the extension rod and the end of the extension rod, the upper end of the transition joint is connected to the transmitter through an external thread, the connection surface is sealed by an end face O-ring, and a mounting end face for installing an electrical penetration and an internal thread for fastening the electrical penetration are provided in the transition joint; the electrical penetration is fastened to the transition joint by a fastening nut, and is fixedly connected to the transition joint through the mounting end face and the internal thread, and the sealing is ensured by the end face sealing O-ring and the side sealing O-ring.

5. A material level meter device with leakage self-diagnosis function according to claim 4, characterized in that: The electrical penetration piece comprises a penetration piece body, a ceramic isolation layer and a pin, wherein: The ceramic isolation layer is arranged between the penetration body and the pin, and is connected and fixed with the penetration body and the pin through a sintering process to achieve insulation and sealing; a connecting thread and a sealing surface for connecting the pressure sensor are arranged at the center of the penetration body, and a sealing ring groove and a sealing end surface are arranged on the outside of the penetration body for sealing, and the penetration body is sealed and connected to the transition joint through a fastening nut.

6. A material level meter device with leakage self-diagnosis function according to claim 4, characterized in that: The pressure sensor comprises a sensor body, a sensor sealing ring, a sensor output lead, and a sensor threaded joint, wherein: A threaded joint is provided at the bottom of the sensor body, and the sensor body is fastened to the electrical penetration piece through the threaded joint, and the sealing is ensured by the sensor sealing ring between the connection surfaces; the pressure sensor is connected to the transmitter through the sensor output lead to transmit the pressure signal.

7. A material level meter device with leakage self-diagnosis function according to claim 6, characterized in that: The level meter cable includes a signal line and a socket. The signal line is inserted into the extension rod and plugged into the pin of the electrical penetration piece through the socket on the outer side of the leakage monitoring component. The other end of the pin is led out through the socket on the other side of the leakage monitoring component and connected to the transmitter.

8. A material level monitoring method implemented by the material level meter device according to claim 7, characterized in that include: The material level meter probe and extension rod extend into the tank to monitor the material level and generate material signals. The pressure sensor monitors the pressure of the pressure chamber in real time and generates pressure signals. Use the level meter cable to transmit material signals and pressure signals to the leakage monitoring component and transmitter, determine the material situation in the tank based on the material signal, and determine whether the level meter needs pressure relief control based on the pressure signal; If the pressure value of the pressure signal is greater than the pressure threshold of the level meter, an alarm signal is generated, and the pressure interface is opened for pressure relief according to the alarm signal; otherwise, the level meter works normally.

9. A method for monitoring a material level meter device with a leakage self-diagnosis function according to claim 8, characterized in that: After the pressure is relieved through the pressure interface, the level meter is externally sealed through the end face sealing O-ring of the leakage monitoring component to ensure that the tank pressure will not leak to the outside.

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