Pipeline pressure testing system and testing method

Abstract

The invention discloses a pipeline pressure testing system and method, and the system comprises a clamping tool and a water pressure testing platform which carries out the pressure testing and pressure maintaining testing of a pipeline, and the clamping tool comprises a pipeline clamping system and a control system. The pipeline clamping system comprises a clamp body, a driving device for driving the clamp body to clamp pipeline flanges and a clamping force detection device for detecting the clamping condition between the pipeline flanges, and the control system is used for controlling the driving device to drive the clamp body according to data detected by the clamping force detection device; and the water pressure test platform is used for carrying out pressure test on the pipeline clamped by the clamping tool. A pipeline clamping system of the tool converts torque to control clamping force through a specific structure and a control system, clamping reliability is achieved, and quick connection, disassembly, remote control and state detection of flange connecting pipelines of specific specifications can be achieved.

Description

Technical Field

[0001] The invention relates to pipeline pressure testing, and in particular to a pipeline pressure testing system and a testing method. Background Art

[0002] The water pressure test of flange pipe fittings is an important means to ensure the quality and safety of pipe fittings. By strictly following the testing process, the sealing, strength and integrity of the pipe fittings can be effectively tested to ensure their reliability and safety in actual use. Before the water pressure test of flange pipe fittings, they need to be installed according to the actual use status to ensure the airtightness of the working state; according to the shipyard's experience data, the preparation time for pipeline assembly and connection in the current pipeline pressure test accounts for more than 80% of the pressure test working hours. Developing agile complete sets of clamping tooling and improving the efficiency of pipeline assembly and connection operations are important guarantees for improving the work rhythm of pipeline pressure testing.

[0003] At present, most flange pipe fittings are installed by bolting flanges, which requires manual screwing of nuts and bolts and special tools to tighten. This process is heavily dependent on the skills and experience of operators. Inconsistent operation leads to inaccurate bolt tightening torque, resulting in poor sealing and bolt damage, which in turn affects the test results and pipe quality. Moreover, manual quality inspection is prone to omissions, and it is impossible to ensure that each installation meets the standards, which poses quality risks and safety hazards. In addition, manual installation is inefficient and consumes a lot of time and labor costs when facing large-scale testing. Therefore, an agile set of clamping tooling and control systems is proposed.

[0004] At present, some flange pipe fittings are installed with quick clamping devices. For example, Chinese patent application with application number 202210552981.5 discloses a clamping claw-type quick clamping device for flange connection. Another example is Chinese patent application with application number 202211462727.2, which discloses a pipeline device and method for rapid centring and disassembly using pipe flanges. The clamping force of these flange pipe quick clamping devices is fixed, and it is impossible to determine whether the pipeline is accurately sealed. Secondly, the equipment is not versatile enough and it is difficult to adapt to flange connection requirements of various specifications and application scenarios. In addition, the ease of operation needs to be improved, and the control accuracy is insufficient, making it difficult to meet occasions where rapid and frequent disassembly and assembly or high sealing requirements are required. Summary of the invention

[0005] Purpose of the invention: In view of the above problems, the present invention provides a pipeline pressure testing system with high control accuracy and high sealing reliability.

[0006] The present invention also provides a testing method for the pipeline pressure testing system.

[0007] Technical solution: To solve the above problems, the present invention adopts a pipeline pressure testing system, including a clamping tool and a water pressure testing platform for performing pressure testing and pressure maintaining tests on pipelines. The clamping tool includes a pipeline clamping system and a control system. The pipeline clamping system includes a clamping body, a driving device for driving the clamping body to clamp the pipeline flange, and a clamping force detection device for detecting the clamping condition between the pipeline flanges. The control system is used to control the driving device to drive the clamping body according to the data detected by the clamping force detection device; the water pressure testing platform is used to perform pressure testing on the pipeline after being clamped by the clamping tool.

[0008] Furthermore, the clamp specifically includes a pressure head, a first shell and a second shell located on both sides of the pressure head. The first shell and the second shell are lightweight designed to reduce weight while ensuring structural strength. The pressure head and the second shell are located on both sides of the pipeline flange respectively. The driving device is fixed to the outside of the first shell to drive the pressure head to approach or move away from the second shell to achieve the clamping or loosening of the pipeline flange; an elastic component is provided at the contact portion between the clamp and the pipeline flange, and its function is to compensate for the back-swinging that may be caused when the motor stops after the clamping action is completed. This back-swinging phenomenon may cause the clamping force to be unstable or decreased. The rubber can effectively compensate for the back-swinging by virtue of its own elastic properties, thereby maintaining the stability of the clamping force and ensuring the working effect and quality of the clamping mechanism; the guide rail at the bottom of the pressure head plays a guiding and supporting role.

[0009] Furthermore, the tops of the first shell and the second shell are arc-shaped and adapted to the pipeline, and the second shell is provided with a plurality of positioning holes, which are respectively adapted to the flanges of pipelines of different types, and the positioning holes and the flange holes of the pipeline are positioned by positioning pins, and the first shell and the second shell are fixedly connected by a plurality of bolt beams, and the two ends of the bolt beams pass through the first shell and the second shell respectively, and nuts are provided on both sides of the first shell and the second shell. The clamping fixture realizes self-centering and orientation of four types of pipe fittings of DN125, DN150, DN250 and DN300 through the rotating pull ring pin and the flange hole, and the side wall of the shell is provided with positioning pins to realize the fixation of the pipe fittings and the clamping fixture. The shell is based on the lightweight design concept, and 2 M12 bolt beams are used on each side of DN125-150, and 3 M12 bolt beams are used on each side of DN250-300 to bear the tension of the side plate. These bolt beams are equipped with a bolt on both sides of the front and rear plates. The outer bolts play a tensile role, while the inner bolts play a compressive role, reducing weight while ensuring structural strength; the shell is equipped with a pressure plate. During the clamping process of the clamping mechanism, a reverse thrust will be generated. This reverse thrust is transmitted to the thrust bearing through the screw, and the thrust bearing then transmits the force to the shell pressure plate, and finally the shell pressure plate bears the pressure, while the harmonic reducer only plays the role of transmitting torque, and the pressure plate plays a protective role for the harmonic reducer. The clamping tooling can realize the quick connection and disassembly, remote control and status detection of DN125, DN150, DN250, and DN300 flange-connected pipelines.

[0010] Furthermore, the driving device includes a servo motor fixed on the first shell, a harmonic reducer fixedly connected to the output end of the servo motor, a ball screw fixedly connected to the output end of the harmonic reducer, and a screw nut sleeved on the ball screw. The bottom of the pressure head is a cylinder and the top is a rectangular parallelepiped. There are concentric holes inside the bottom cylinder. The pressure head is fixedly sleeved on the screw nut. The servo motor and the harmonic reducer provide torque to the ball screw. The servo motor drives the ball screw to rotate through the harmonic reducer. The rotation of the ball screw drives the screw nut to move, thereby driving the pressure head to approach or move away from the second shell. The ball screw, the screw nut and the pressure head are used in combination. The clamp is sleeved on the screw nut to convert the torque into a clamping force on the flange surface of the pipe fitting. The servo motor adopts an integrated drive and control unit and has a waterproof function. The harmonic reducer and the motor cooperate to output a torque of 100 Nm. The two are placed outside the shell, reducing the shell volume and meeting the requirements of lightweight equipment; the clamp body is connected to the front and rear side shells by a retractable bellows, which is sleeved on the screw and filled with lubricating grease inside. Its function is to provide lubrication for the support bearings at the front and rear ends of the screw and the screw itself.

[0011] Furthermore, the clamping force detection device collects pressure, current, and position signals for closed-loop control of the motor. The clamping force detection device includes a pressure sensor, a photoelectric induction switch, a displacement sensor, and a current sensor sleeved on the lead screw nut. A clamping portion is provided at the end of the lead screw nut. The pressure sensor adopts an annular hollow spoke-type pressure sensor. Since the structural dimensions of the spoke-type pressure sensor are referred to when designing the specific structure of the clamp, the pressure sensor can be sleeved between the lead screw nut and the pressure head. During the clamping process, the lead screw nut transmits the clamping force to the pressure sensor, and the pressure sensor transmits the force to the pressure head, thereby achieving the purpose of measuring pressure; the pressure sensor The force sensor is responsible for the positive stroke signal acquisition, that is, measuring the clamping force. When the clamping force reaches the requirement, the signal is transmitted to the motor controller, and the controller stops the motor. The photoelectric induction switch is used to sense the retreat position of the pressure head after the clamping is completed. When the clamping work is completed, the clamp body retreats to the specified position, and the photoelectric induction switch sends the collected signal to the motor controller, and the controller stops the motor. A sealing ring is set between the two clamping pipeline flanges, and the displacement sensor is used to measure the deformation of the sealing ring; the current sensor is used to collect the current value, and the control system calculates the output torque of the motor according to the collected current value, thereby controlling the clamping speed of the pressure head. The clamping force, position and other status information collected by the sensor module in real time are fed back to the main control unit through the communication network. The main control unit analyzes and compares these feedback information. If it is found that the clamping state of a clamping tool is beyond the allowable range from the set value, the main control unit sends an adjustment instruction to the slave control module, and the slave control module fine-tunes the clamping action according to the adjustment instruction to ensure that all clamping tools reach the predetermined pipeline clamping state synchronously.

[0012] The control system includes a DC power supply, a 32-bit single-chip microcomputer controller, and a wireless communication module. The tooling is powered by DC, and the battery is installed in the protective shell of the fixture. Due to the different power supply voltage requirements of various devices inside the tooling, a 48-volt lithium iron phosphate battery is used with a step-down module to power each component separately. The upper computer and the lower computer of the tooling in the control system use wireless communication, communicating through the LORA wireless module, and RS485 communication between the wireless module and the upper computer. The lower computer processor STM32 communicates with the servo motion controller through CANopen, and the motion controller is connected to the motor drive to achieve servo control. The axial displacement of the clamping block is accurately controlled by the motor servo system, thereby regulating the compression amount of the sealing ring. At the same time, the clamping force and the locking motor torque are fed back by the sensor to achieve synchronous servo closed-loop pre-tightening and locking. The clamping tooling can be clamped synchronously on both sides according to the predetermined speed and clamping force. A touch screen control system is installed on the fixture to communicate with STM32 to achieve local status display and control.

[0013] The wireless communication module needs to meet the following functions:

[0014] 1) Status monitoring function: It can monitor the status of the lower computer or equipment, sensor data, signal input, etc. in real time, and collect relevant data to display in the software, so that users can intuitively understand the real-time status of the equipment.

[0015] 2) Control execution function: With the help of the software user interface, users can send commands, set parameters, control execution actions, etc., thereby achieving effective control of the lower computer or equipment.

[0016] The agile clamping tooling control software for pipeline pressure testing takes remote precise control and real-time monitoring of tooling status as its core. In terms of page layout, it is divided into a real-time monitoring area, which displays key data such as pressure, displacement, and current in real time in the form of numbers and charts; the control operation area is equipped with various control buttons, such as start, stop, speed adjustment, and clamping force, etc., and is also equipped with a parameter input box for users to flexibly set operating parameters; the status display area intuitively presents the operating status of the equipment, including the motor operation status, tooling connection status, etc.; the data recording and query area is convenient for users to view historical operation data, and supports filtering and querying by time, pipeline specifications and other conditions; once the alarm prompt area detects equipment abnormality or parameters exceed the threshold, it will immediately issue an audible and visual alarm to remind operators to deal with it in time to ensure safe and smooth operations.

[0017] Furthermore, the clamping tooling also includes a supporting device, which includes rolling rollers and a movable telescopic platform, the rolling rollers include a supporting part and a plurality of rollers arranged on the supporting part, the rotating plane of the rollers is parallel to the end face of the pipeline flange, and the rollers are in direct contact with the pipeline flange, and the rollers rotate synchronously when the pipeline flange rotates, which is used to align the flange holes when the two pipeline flanges are docked, ensuring the alignment of the bolt holes on both sides during the installation process, and facilitating the installation of the locating pins; the mobile lifting platform is a scissors-fork type lifting platform, which is used to transport, support and adjust the height of the clamping tooling, thereby reducing the labor intensity of workers.

[0018] The present invention also adopts a testing method of the above pipeline pressure testing system, comprising the following steps:

[0019] Step 1: Place the pipeline to be tested at the test site;

[0020] Step 2: Place the flange of the test pipe in the clamp;

[0021] Step 3: Start the control system to control the clamping tool to clamp the flange of the test pipeline and connect the test pipeline into a pipeline system;

[0022] Step 4: Arrange an air release valve at the highest point of the pipe system, arrange a relief valve at the end of the pipe system, and install a plug;

[0023] Step 5: Arrange a pressure gauge from the outlet of the pressure pump station to the connecting pipe section of the pipe system;

[0024] Step 6: Start the water pressure control system, inject water into the pipes in the pipe system, and exhaust the air;

[0025] Step 7: After the air is exhausted, pressurize the pipe system to the holding pressure and find defects;

[0026] Step 8: Release the pressure after the pressure holding test is completed;

[0027] Step 9: Use the control system to control the clamping fixture to release the flange of the pipeline and remove the pipeline.

[0028] Furthermore, the step 1 includes a plurality of test pipelines, and the test pipelines are clamped by a plurality of clamping tools; the step 3 starts the control system to control the clamping tools to clamp the flanges of the test pipelines, and the specific steps of connecting the test pipelines into a pipeline system are as follows:

[0029] Step 31: Check the clamping systems of each pipeline to ensure that the test pipeline is in place and initially fix each clamp;

[0030] Step 32: The control system receives the pre-clamping instruction, controls the driving device to clamp the flange of the test pipeline with low torque, and the clamping force detection device collects clamping force data;

[0031] Step 33: After all clamps pre-clamp the flange of the test pipeline, the hydraulic test platform sends a clamping force control instruction, and the control system controls the driving device to clamp the test pipeline flange according to the instruction until the clamping force data collected by the clamping force detection device reaches the parameter in the control instruction;

[0032] Step 34: The operator sends control instructions in real time through the water pressure test platform, and the control system controls the drive device according to the control instructions until the clamping function requirements of the test pipeline are completed.

[0033] The hydraulic test platform serves as the main control unit, and each clamping fixture is equipped with an independent control system as a slave control module. The main control unit is responsible for sending unified control instructions, coordinating the work of each slave control module, receiving instructions from the main control unit from the slave control module, driving the local pipe clamping system and drive control system to perform corresponding actions, and providing real-time feedback on status information.

[0034] Furthermore, in step 33, the hydraulic pressure test platform attaches a timestamp when sending the clamping force control instruction, and the control system starts the delay according to the timestamp to ensure that all clamping fixtures act at the same time, and the hydraulic pressure test platform regularly issues synchronization signals to ensure clock consistency and compensate for speed deviations caused by hardware differences; speed coordination control is to set different speeds for each clamping fixture according to the material, size and position of the pipeline, and the main control unit monitors the feedback and adjusts the motor speed to make the speed deviation within a reasonable range.

[0035] The hydraulic test platform includes a state detection function, which includes sensor data detection and fault diagnosis model. Sensor data detection obtains sensor data such as pressure, position, current, etc. collected by the sensor, and analyzes through fusion algorithm to determine the pipeline status, such as leakage and looseness through changes in pressure and clamping force data. The fault diagnosis model is used to establish a machine learning or deep learning model with normal working data as a sample, analyze and predict in real time, find anomalies, issue warnings, and provide fault causes and solutions.

[0036] The water pressure testing platform also includes a pressure maintenance linkage function, including a pressure maintenance strategy and a linkage control logic. The pressure maintenance strategy means that when the pressure test is performed after the pipeline is clamped, the main control unit adjusts the clamping force to stabilize the pressure according to the preset pressure maintenance value. When the pressure drops, it determines whether it is a normal fluctuation or a leak based on the rate and amplitude of change. If it fluctuates, it will be fine-tuned to compensate. If it leaks, it will alarm and stop maintaining the pressure. The linkage control logic means that when maintaining the pressure, if a pipeline needs emergency treatment (such as rapid pressure relief), the main control unit will send a linkage instruction to other slave control modules to adjust the pressure, such as increasing the force of other pipelines to prevent damage during rapid pressure relief.

[0037] Furthermore, the test site is arranged at the pressure test station of the pipe processing workshop. In the post-welding process of the pipe fittings, the test site includes a safety fence around it, a safety door set on the safety fence, a drainage ditch set around it, a cover plate with holes set on the drainage ditch, and a water pressure test platform and auxiliary equipment set inside the safety fence and outside the drainage ditch. The test pipeline is placed in the space surrounded by the drainage ditch, and a water inlet is set in the space surrounded by the drainage ditch. The safety door is used to ensure safety. The test site is easy to operate and can effectively support work such as pressure testing, which is conducive to equipment installation, operation, maintenance and management.

[0038] The whole process monitoring and real-time display of system pressure ensures the stability of the pressure test process, simple control and accurate results; manual and automatic dual control modes are set to meet the needs of different scenarios; equipped with segmented pressure test and pressure maintenance functions, and the rise / fall rate is adjustable, and can be operated according to the set pressure curve; integrated digital sensing equipment to realize the collection and monitoring of the pressure of each pressure test pipeline, display and record data through intelligent instruments, generate curves and reports; carry out mechanical system dynamics optimization design and ultra-precision motion control technology research of full-width marking and printing equipment to improve the positioning accuracy and equipment efficiency of marking and printing machines; allow the pressure test parameters to be flexibly set according to the requirements of pipeline strength tests, It also supports parameter saving and quick call to reduce repeated manual input; it has the function of exporting test data and reports; the equipment has the functions of fast water injection, automatic pressure maintenance, pressurization during the test and pressure relief after the test, and the pressure test pump is equipped with a safety valve; an emergency stop function and a safety protection device are set, which can automatically stop pressurization and relieve pressure when a leak occurs during the test to ensure personnel safety; the test pipeline is equipped with pointer and electronic pressure gauges, which support local and remote display of pressure; flange connection pipelines are used to achieve quick connection and disassembly; agile clamping tooling supports remote control and status detection; at the same time, it has reliable safety protection, alarm and insurance functions to ensure the safety and smooth progress of operations in all aspects.

[0039] Beneficial effects: Compared with the prior art, the significant advantage of the present invention is that the pipe clamping system of the tooling can convert torque to control the clamping force through a specific structure and control system to achieve clamping reliability, and can realize the rapid connection, disassembly, remote control and status detection of flange-connected pipes of specific specifications. The drive control system adopts wireless communication and closed-loop control; the supporting auxiliary equipment has a positioning support function. The control method of multi-pipeline synchronous clamping, status detection method, pressure maintenance linkage and other functions have been added, which can monitor the system pressure throughout the process and accurately display the pressure. The pressure test is stable, the control is simple, and the results are accurate. It has both manual and automatic control modes, and the segmented pressure test, pressure maintenance and rate adjustment functions are complete, and the pressure test can be carried out according to the set curve. The integrated digital sensing equipment can collect pressure and position data, and the intelligent instrument can record and generate reports. It can also conveniently set and call parameters, and efficiently export a variety of test information. The equipment has complete water injection, pressure maintenance and pressure relief functions and is equipped with a safety valve, emergency stop and protective devices to ensure safety. The pipeline pressure gauge supports local and remote display, the flange connection is fast and convenient, the clamping tooling can be remotely controlled and detected, and the safety protection, alarm and insurance functions are reliable. When using the agile clamping tooling, the overall efficiency of water pressure detection is improved by more than 40% compared with the manual assembly mode. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 It is a schematic diagram of the overall structure of the pipeline pressure testing system in the present invention.

[0041] Figure 2 It is a schematic diagram of the structure of the clamping tool in the present invention.

[0042] Figure 3 It is a structural schematic diagram of the pipeline clamping system in the present invention.

[0043] Figure 4 It is a schematic diagram of the working conditions of the DN125 / 150 type and DN250 / 300 type pull ring latch in the present invention.

[0044] Figure 5 It is a schematic diagram of the functional modules of the pipeline pressure testing system in the present invention.

[0045] Figure 6 Schematic diagram of internal information communication of the pipeline pressure testing system in the present invention.

[0046] Figure 7 It is a schematic flow chart of the pipeline pressure testing method in the present invention. DETAILED DESCRIPTION

[0047] Example 1

[0048] like Figure 1As shown, a pipeline pressure test system in this embodiment includes an agile set of clamping tooling and a water pressure test platform. The equipment is arranged at the pressure test station in the pipe processing workshop, after the pipe welding process, covering an area of ​​30 meters × 15 meters. The overall layout of this equipment composition is rectangular, surrounded by a safety fence 4, and a safety door 5 is set in the upper right corner to ensure the safety of the operation area in all directions. The pressure test bench 9 stands on the upper left position. As the core and key part of the entire equipment, it undertakes the important responsibility of pressure testing components such as pipelines. It may be equipped with a variety of pressure control, measurement and monitoring devices to accurately control various parameters during the test process. Immediately to its right is the auxiliary equipment area 10, which brings together various types of equipment that provide power, support and auxiliary functions for the pressure test bench, such as a water pump that provides water pressure, a control system device that controls and adjusts the test process, and related instruments for data acquisition and processing. They work closely with the pressure test bench to jointly build a complete and efficient test system. On the left side of the layout diagram, there is a water inlet 8, which is the source of water for the entire system. Its location design facilitates smooth connection with external water sources, providing a stable water source guarantee for pressure testing and other operations. The drainage ditch 6 and the perforated cover plate 7 in the lower right corner are important facilities for wastewater discharge. The perforated cover plate can effectively filter larger impurities, prevent blockage of the drainage pipe, ensure smooth drainage and clean site. Its location is arranged at the edge of the site, which does not affect other equipment and operations in the test area, and can efficiently complete the wastewater discharge treatment work. In addition, the pipeline to be tested is placed in the middle of the test station. Valves, sensors and other components may be installed on the pipeline to accurately control water flow, measure pressure and other parameters to meet the strict requirements of pressure testing and related operations. The equipment composition layout has clear and definite functional divisions, meticulous and comprehensive safety protection measures, and smooth and natural operation procedures. It can effectively support the smooth development of pressure testing and other related work. At the same time, it has significant convenience and efficiency in the installation, operation, maintenance and management of the equipment.

[0049] like Figure 2 As shown in the figure, due to the large size difference between the four flanges, two types of clamping fixtures are used. Professional staff will move the pipelines to be tested to the designated test site according to the specific specifications and models of the pipelines, and arrange them neatly according to the pre-planned layout to ensure that subsequent operations can be carried out smoothly. For those pipes suitable for agile clamping fixtures, the staff needs to carefully check the key information such as the size and material of the pipes, and select the matching agile clamping fixtures from the storage area.

[0050] like Figure 3 and Figure 4As shown, the clamping tool 1 includes a pipeline clamping system, a control system, and a supporting device. The pipeline clamping system includes a clamp body, a driving device for driving the clamp body to clamp the pipeline flange, and a clamping force detection device for detecting the clamping condition between the pipeline flanges. The control system is used to control the driving device to drive the clamp body according to the data detected by the clamping force detection device. The clamp body includes a pressure head 27, a first shell 34 and a second shell 33 located on both sides of the pressure head 27. The pressure head 27 and the second shell 33 are respectively located on both sides of the pipeline flange. The driving device is fixed to the outside of the first shell to drive the pressure head 27 to approach or move away from the second shell 33 to achieve the clamping or loosening of the pipeline flange. An elastic component is provided at the contact portion between the clamp head 27 and the pipeline flange. In this embodiment, the elastic component is a rubber block, and its function is to compensate for the backlash that may be caused when the motor (21) stops after the clamping action is completed. This backlash phenomenon may cause instability or decrease in the clamping force. The rubber can effectively compensate for the backlash by virtue of its own elastic properties, thereby maintaining the stability of the clamping force and ensuring the working effect and quality of the clamping mechanism; the guide rail 31 at the bottom of the pressure head plays a guiding and supporting role.

[0051] The tops of the first shell 34 and the second shell 33 are arc-shaped and adapted to the pipeline. The second shell 33 is provided with a plurality of positioning holes, and the plurality of positioning holes are respectively adapted to the flanges of pipelines of different types. The positioning holes and the flange holes of the pipeline are positioned by positioning pins 32. The first shell 34 and the second shell 33 are fixedly connected by a plurality of bolt beams 28. The two ends of the bolt beams 28 pass through the first shell 34 and the second shell 33 respectively, and nuts are provided on both sides of the first shell 34 and the second shell 33.

[0052] The driving device includes a servo motor 21 fixed on the first housing, a harmonic reducer 22 fixedly connected to the output end of the servo motor 21, a ball screw 24 fixedly connected to the output end of the harmonic reducer 22, and a screw nut 25 sleeved on the ball screw 24. The pressure head 27 is fixedly sleeved on the screw nut 25. The servo motor 21 drives the ball screw 24 to rotate through the harmonic reducer 22. The rotation of the ball screw 24 drives the screw nut 25 to move, thereby driving the pressure head 27 to move closer to or away from the second housing 33. A bellows 23 is fixedly arranged between the screw nut 25 and the first housing and the second housing. The bellows is sleeved outside the ball screw and is filled with lubricating grease.

[0053] The clamping force detection device includes a pressure sensor 26, a photoelectric induction switch, a displacement sensor, and a current sensor which are sleeved on the lead screw nut 25. A clamping portion is arranged at the end of the lead screw nut 25, and the pressure sensor 26 is located between the clamping portion of the lead screw nut 25 and the pressure head 27. The photoelectric induction switch is used to sense the retracted position of the pressure head after the clamping is completed; a sealing ring is arranged between the two clamping pipeline flanges, and the displacement sensor is used to measure the deformation of the sealing ring; the current sensor is used to collect the current value, and the control system calculates the output torque of the motor according to the collected current value, thereby controlling the clamping speed of the pressure head 27.

[0054] The supporting device includes rolling rollers 12 and a mobile telescopic platform 11. The mobile telescopic platform can realize the movement and height adjustment of the clamping tool, and the rolling roller realizes the centering and positioning of the flange axis of the pipe fitting. The flange connection of the pipe fitting to be inspected is symmetrically clamped using two agile sets of clamping tools. To facilitate the movement and installation of the clamping tool, rolling rollers and a mobile telescopic platform are arranged along the flange connection of the pipeline. The rollers are in direct contact with the pipe flange to ensure the alignment of the bolt holes on both sides during the installation process, which is convenient for the installation of the locating pins. At the same time, a mobile lifting platform is arranged near the flange connection to transport the clamping tool to the predetermined working position, and then perform the clamping operation to reduce the labor intensity of the workers. The mobile telescopic platform and rolling rollers place the agile clamping tool in the correct position of the flange pipe fitting, and make all preparations before installation.

[0055] The control system includes a DC power supply, a 32-chip motion controller 29, and a wireless communication module. The tooling is powered by DC, and the battery is installed in the fixture protective shell. Due to the different power supply voltage requirements of various devices inside the tooling, a 48-volt lithium iron phosphate battery is used with a step-down module to power each component separately; the lower computer processor STM32 communicates with the servo motion controller through CANopen, and the motion controller 29 is connected to the motor drive. The axial displacement of the clamping block is accurately controlled by the motor servo system, thereby regulating the compression amount of the sealing ring. At the same time, the clamping force and the locking motor torque are fed back by the sensor to achieve synchronous servo closed-loop pre-tightening and locking. The clamping tooling can be clamped synchronously on both sides according to the predetermined speed and clamping force. A touch screen 30 control system is installed on the fixture to communicate with the STM32 to achieve local status display and control. The water pressure test platform serves as the main control unit, and the control system equipped in each agile clamping tooling set serves as an independent slave control module. The main control unit is responsible for sending unified control instructions, coordinating the work of the slave control modules, receiving instructions from the main control unit, driving the local pipe clamping system and drive control system to perform corresponding actions, and providing real-time feedback on status information.

[0056] like Figure 5As shown in the figure, after the self-check is completed, the main control unit is powered on, and each slave control module is initialized and checked in turn to confirm whether the hardware status of each clamping fixture is normal, including whether the connection of the motor, sensor, actuator and other equipment is normal, and whether the communication link is unobstructed. If an abnormality is found, the main control unit will issue an alarm and display the fault information, and the operator will troubleshoot and repair it according to the prompts. The operator enters the clamping instruction in the human-computer interaction interface of the hydraulic test platform, and the main control unit sends the instruction to each slave control module in turn according to the address sequence of the slave control module. The instruction content includes parameters such as clamping force, clamping stroke, and clamping speed. Each parameter can be preset and adjusted according to the flange connection pipeline of different specifications. After receiving the clamping instruction, each slave control module controls the local drive control system to drive the pipeline clamping system according to the instruction parameters. The drive control system drives the lead screw, hydraulic cylinder or other actuators through the motor to realize the clamping operation of the pipeline. During the clamping process, each slave control module collects the data of the clamping force sensor and position sensor in real time to determine whether the clamping state meets the set requirements. The staff followed the standard operating procedures and connected the tested pipes with the help of the start-up tooling to form a complete pipe system. During the connection process, they paid close attention to the pipe docking to ensure that the connection was tight and without deviation.

[0057] like Figure 4 As shown, the tooling adopts a bilateral symmetrical clamping scheme, and the clamping is completed by the collaboration of the self-centering and orientation module, the synchronous servo closed-loop pre-tightening and locking module and the detection system. The clamping bodies are symmetrically set on both sides of the pipeline connection flange, and the self-centering and orientation of the pipe fittings are realized through the pull ring positioning pin and the flange hole; the servo motor drives the screw to rotate through the harmonic reducer, drives the clamping block to axially clamp the flange end face, and sets a sealing ring on the flange joint surface; detects the position, clamping force, and deformation of the sealing ring, and accurately controls the axial displacement of the clamping block through the motor servo system, regulates the compression of the sealing ring, and at the same time feeds back the clamping force and the locking motor torque to realize bilateral synchronous servo closed-loop pre-tightening and locking, and synchronously clamps both sides according to the predetermined speed and clamping force.

[0058] like Figure 6 As shown, in order to avoid line interference during operation, the upper computer and the lower computer of the tooling adopt wireless communication. The tooling adopts DC power supply, the battery is installed in the fixture protection shell, and a DC servo motor is used. The lower computer processor STM32 communicates with the servo motion controller through CANopen, and the motion controller 29 is connected to the motor drive to realize servo control. A touch screen control system is installed on the fixture to communicate with STM32 to realize local status display and control.

[0059] The local processor is connected to the photoelectric sensor switch, displacement sensor, pressure sensor, and torque sensor through the IO module. The photoelectric sensor switch is used to detect the position status of the positioning pin, and the displacement sensor is used to measure the deformation of the sealing ring. The lower limit of the compression is determined according to the ultra-high pressure sealing reliability test, and the upper limit of the compression value is determined according to the law of change of the fatigue life of the sealing ring with the compression. The axial displacement of the clamping block is accurately controlled by the motor servo system, thereby regulating the compression of the sealing ring, and the clamping force and the locking motor torque are fed back at the same time to achieve synchronous servo closed-loop pre-tightening and locking. The clamping fixture can be clamped synchronously on both sides according to the predetermined speed and clamping force. The lower computer and the upper computer communicate through the LORA wireless module, and the wireless module and the upper computer use RS485 communication.

[0060] like Figure 7As shown, in order to ensure the safety and accuracy of the test process, an air release valve is installed at the highest point of the pipeline so that the air in the pipeline can be discharged smoothly during the water injection and pressurization process; a relief valve is arranged at the terminal of the pipeline to safely release the pressure in the pipeline after the test; at the same time, according to the specific conditions of the pipeline, the corresponding plug is assembled to prevent liquid leakage and ensure the sealing of the entire pipeline system. From the outlet of the pressure pump station to the pipeline connection section, the staff strictly follows the specifications and selects the appropriate position and method to arrange the pressure gauge to ensure that the pressure changes at different positions of the pipeline can be accurately measured, providing a reliable basis for subsequent pressure control and data analysis, and ensuring the accuracy of the test results. After completing the above preparations, the staff starts the water pressure control system. The system first performs initialization settings, loads the preset parameters and control programs, and checks and calibrates the water pressure pump, sensor, valve and other equipment to ensure that the water pressure control system can operate stably and meet the test requirements. After startup, the water pressure control system slowly injects treated water into the pipeline according to the set procedures and parameters. During the water injection process, the water flow rate and pressure are adjusted to ensure that the water can smoothly fill the entire pipeline, and the air in the pipeline is gradually emptied to ensure the stability of the test environment and the reliability of the test results. After confirming that the air in the pipeline is completely emptied, the water pressure control system automatically or manually starts the pressurization program according to the preset pressure curve and rate, accurately controls the rising speed and pressure value of the water pressure, ensures that the pressurization process is stable and safe, avoids damage to the pipeline and test equipment due to sudden pressure changes, and ensures the accuracy of the test results. After reaching the predetermined pressure, the system enters the pressure maintenance stage and continues to maintain stable pressure according to the test requirements. During this period, the staff carefully looks for possible defects such as weld leakage and poor sealing by observing the appearance of the pipeline, listening for leakage sounds, and checking whether the pressure gauge value is stable, so as to ensure the quality and safety of the pipeline. When the pressure holding time reaches the specified test time, the water pressure control system starts the pressure relief operation according to the predetermined procedure, slowly reducing the pressure in the pipeline to ensure that the pressure relief process is safe and smooth, avoiding the impact on the pipeline and equipment caused by the sudden drop in pressure, while protecting the safety of the staff and preventing accidents. Finally, for the pipeline connected with the clamping fixture, the staff operates the clamping fixture control system and sends a release command, and the fixture automatically loosens the clamp on the pipeline; for other pipeline parts that are manually connected, the staff manually removes the connection parts and removes the pipeline from the test equipment to complete the entire test process, and cleans and organizes the test equipment and site to prepare for the next test.

Claims

1. A pipeline pressure testing system, characterized in that: The invention comprises a clamping tool (1) and a water pressure test platform for performing pressure test and pressure maintenance test on a pipeline, wherein the clamping tool (1) comprises a pipeline clamping system and a control system, wherein the pipeline clamping system comprises a clamping body, a driving device for driving the clamping body to clamp the pipeline flange, and a clamping force detection device for detecting the clamping condition between the pipeline flanges, and the control system is used to control the driving device to drive the clamping body according to data detected by the clamping force detection device; the water pressure test platform is used to perform pressure test on the pipeline after being clamped by the clamping tool.

2. The pipeline pressure testing system according to claim 1, characterized in that: The clamp body comprises a pressure head (27), a first shell (34) and a second shell (33) located on both sides of the pressure head (27); the pressure head (27) and the second shell (33) are located on both sides of the pipeline flange respectively; the driving device is fixed to the outside of the first shell and is used to drive the pressure head (27) to approach or move away from the second shell (33) to achieve the clamping or loosening of the pipeline flange; an elastic component is arranged at the contact part between the clamp (27) and the pipeline flange.

3. The pipeline pressure testing system according to claim 2, characterized in that: The tops of the first shell (34) and the second shell (33) are arc-shaped and adapted to the pipeline. The second shell (33) is provided with a plurality of positioning holes, and the plurality of positioning holes are respectively adapted to flanges of pipelines of different models. The positioning holes and the flange holes of the pipeline are positioned by positioning pins (32). The first shell (34) and the second shell (33) are fixedly connected by a plurality of bolt beams (28). The two ends of the bolt beams (28) pass through the first shell (34) and the second shell (33) respectively, and nuts are provided on both sides of the first shell (34) and the second shell (33).

4. The pipeline pressure testing system according to claim 2, characterized in that: The driving device comprises a servo motor (21) fixed on the first housing, a harmonic reducer (22) fixedly connected to the output end of the servo motor (21), a ball screw (24) fixedly connected to the output end of the harmonic reducer (22), and a screw nut (25) sleeved on the ball screw (24); the pressure head (27) is fixedly sleeved on the screw nut (25); the servo motor (21) drives the ball screw (24) to rotate through the harmonic reducer (22); the rotation of the ball screw (24) drives the screw nut (25) to move, thereby driving the pressure head (27) to approach or move away from the second housing (33); a bellows is fixedly arranged between the screw nut (25) and the first housing and the second housing; the bellows is sleeved outside the ball screw and is filled with lubricating grease.

5. The pipeline pressure testing system according to claim 2, characterized in that: The clamping force detection device comprises a pressure sensor (26) sleeved on the screw nut (25), a photoelectric induction switch, a displacement sensor, and a current sensor. A clamping portion is provided at the end of the screw nut (25). The pressure sensor (26) is located between the clamping portion of the screw nut (25) and the pressure head (27). The photoelectric induction switch is used to sense the retreat position of the pressure head after clamping. A sealing ring is provided between two clamping pipeline flanges. The displacement sensor is used to measure the deformation of the sealing ring. The current sensor is used to collect current values. The control system calculates the output torque of the motor according to the collected current values, thereby controlling the clamping speed of the pressure head (27).

6. The pipeline pressure testing system according to claim 2, characterized in that: The clamping tool (1) also includes a supporting device, which includes a rolling roller (12) and a movable telescopic platform (11). The rolling roller (12) includes a supporting portion and a plurality of rollers arranged on the supporting portion. The rotation plane of the roller is parallel to the end face of the pipeline flange, and the roller is in direct contact with the pipeline flange. When the pipeline flange rotates, the roller rotates synchronously, which is used for aligning the flange holes when the two pipeline flanges are connected. The movable lifting platform (11) is a scissor-fork type lifting platform, which is used to transport and support the clamping tool and adjust the height of the clamping tool.

7. A method for testing a pipeline pressure testing system according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Place the pipeline to be tested at the test site; Step 2: Place the flange of the test pipe in the clamp; Step 3: Start the control system to control the clamping tool to clamp the flange of the test pipeline and connect the test pipeline into a pipeline system; Step 4: Arrange an air release valve at the highest point of the pipe system, arrange a relief valve at the end of the pipe system, and install a plug; Step 5: Arrange a pressure gauge from the outlet of the pressure pump station to the connecting pipe section of the pipe system; Step 6: Start the water pressure control system, inject water into the pipes in the pipe system, and exhaust the air; Step 7: After the air is exhausted, pressurize the pipe system to the holding pressure and find defects; Step 8: Release the pressure after the pressure holding test is completed; Step 9: Use the control system to control the clamping fixture to release the flange of the pipeline and remove the pipeline.

8. The testing method according to claim 7, characterized in that: The specific steps of step 1 including a plurality of test pipelines, clamping the test pipelines by a plurality of clamping fixtures; and step 3 starting the control system to control the clamping fixtures to clamp the flanges of the test pipelines, and connecting the test pipelines into a pipeline system are as follows: Step 31: Check the clamping systems of each pipeline to ensure that the test pipeline is in place and initially fix each clamp; Step 32: The control system receives the pre-clamping instruction, controls the driving device to clamp the flange of the test pipeline with low torque, and the clamping force detection device collects clamping force data; Step 33: After all clamps pre-clamp the flange of the test pipeline, the hydraulic test platform sends a clamping force control instruction, and the control system controls the driving device to clamp the test pipeline flange according to the instruction until the clamping force data collected by the clamping force detection device reaches the parameter in the control instruction; Step 34: The operator sends control instructions in real time through the water pressure test platform, and the control system controls the drive device according to the control instructions until the clamping function requirements of the test pipeline are completed.

9. The testing method according to claim 8, characterized in that: In step 33, the hydraulic test platform sends a clamping force control instruction with a timestamp, and the control system starts a delay according to the timestamp to ensure that all clamping fixtures act at the same time, and the hydraulic test platform regularly issues a synchronization signal to ensure that the clock is consistent; The water pressure test platform includes a state detection function, which includes sensor data detection and fault diagnosis model. Sensor data detection obtains the data collected by the sensor and analyzes it through a fusion algorithm to determine the pipeline status; The fault diagnosis model is used to establish a machine learning or deep learning model with normal working data as samples for real-time analysis and prediction; The water pressure testing platform also includes a pressure maintenance linkage function, which is used to determine whether it is a normal fluctuation or a leak based on the rate and amplitude of pressure drop. When the pressure fluctuates normally, the pressure is fine-tuned for compensation. When a leak occurs, an alarm is issued and pressure maintenance is stopped.

10. The testing method according to claim 9, characterized in that: The test site comprises a safety fence (4) surrounding the site, a safety door (5) arranged on the safety fence, a drainage ditch (6) arranged around the site, a cover plate with holes (7) arranged on the drainage ditch, and a water pressure test platform (9) and auxiliary equipment (10) arranged inside the safety fence and outside the drainage ditch. The test pipeline is placed in the space surrounded by the drainage ditch, and a water inlet is arranged in the space surrounded by the drainage ditch.

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