Under-pressure on-line spark-free pipeline cutting device for heat conduction system

Abstract

The invention relates to the technical field of industrial pipeline equipment maintenance, in particular to a heat conduction system under-pressure online no-spark pipeline cutting device which comprises a protective cover, a cutting unit, an anti-explosion freezing unit and a controller. According to the invention, by integrating sparkless ceramic cutting, two-way freezing plugging and closed protection collection technologies, safe and environment-friendly online under-pressure cutting and replacement operation of the heat-conducting oil pipeline is realized under the condition that system production halt and medium emptying are not needed, and huge economic loss caused by production halt is thoroughly avoided; the explosion risk caused by traditional cutting sparks is completely eliminated, pollution to the environment due to leakage of toxic media is effectively prevented, and the method has the remarkable comprehensive benefits of intrinsic safety, high efficiency, economy and environmental protection.

Description

Technical Field

[0001] This invention relates to the field of industrial pipeline equipment maintenance technology, and in particular to a pressurized online sparkless pipeline cutting device for heat conduction systems. Background Technology

[0002] In the production processes of petrochemicals, chemical fibers, and other fields, pipeline systems using easily solidified heat transfer oil media such as biphenyl-diphenyl ether are widely used. After long-term operation, valves and other components in these systems may become damaged and require replacement. Existing technologies typically require a complete system shutdown, complete drainage and replacement of the heat transfer oil in the pipelines, and thorough cleaning before cutting and welding can be performed. Alternatively, traditional pressurized tapping and plugging techniques can be used, which are complex processes requiring large amounts of equipment.

[0003] Existing technologies and methods have the following main problems: system shutdown for cleaning and venting can lead to huge production and economic losses, and the operation cycle is very long; traditional cutting methods are prone to generating high-temperature sparks, and the flammable and explosive medium vapors remaining in the pipeline are easily ignited, posing serious fire and explosion safety hazards; at the same time, the leakage of toxic and harmful media during the operation can cause environmental pollution and harm to human health. Therefore, a heat-conducting system pressurized online sparkless pipeline cutting device is proposed. Summary of the Invention

[0004] To address the shortcomings of the aforementioned technologies, this invention provides a pressurized online sparkless pipe cutting device for heat conduction systems, which enables online pipe cutting for valve replacement.

[0005] This invention discloses a pressurized online sparkless pipe cutting device for a heat conduction system, comprising:

[0006] A protective cover, installed on the outer wall of the pipe cutting area, is used for cutting protection;

[0007] The cutting unit, housed within a protective cover, is used for cutting pipes;

[0008] Explosion-proof refrigeration unit, including:

[0009] Spring-loaded telescopic refrigeration coils are wound around both ends of the cut-off section of the pipe.

[0010] Dual refrigeration compressors are connected to spring-loaded telescopic refrigeration coils via pipes to supply refrigerant to the coils.

[0011] The controller is used to control the coordinated operation of the cutting unit and the explosion-proof freezing unit.

[0012] The cutting unit includes a circular fixed rail with at least three threaded clamping rods evenly spaced on it. These threaded clamping rods are threadedly connected to the fixed rail. A toothed ring is rotatably connected to the inner wall of the fixed rail. An electric slide rail is radially fixed to the side wall of the toothed ring. A blade holder is mounted on the electric slide rail, and ceramic cutting blades are fixed on the blade holder, with all the blade edges of the ceramic cutting blades on the same radial plane. A drive motor is fixedly mounted on the fixed rail, and the output end of the drive motor has a gear that meshes with the toothed ring. The controller is electrically connected to the drive motor and the electric slide rail.

[0013] The fixed rail and the movable toothed ring are both composed of two semi-circular structures fixed together by bolts.

[0014] The protective cover consists of two parts spliced ​​together and fitted onto the outer wall of the pipe. An exhaust pipe is installed on the protective cover to discharge the gas inside the pipe.

[0015] A mooring plate is slidably installed at the lower end of the inside of the protective cover, with one end of the mooring plate extending to the outside of the protective cover in the sliding direction.

[0016] The number of spring-loaded telescopic refrigeration coils at both ends of the pipe cut-off point is divided into two, and both are connected in parallel to the dual refrigeration compressor.

[0017] Both sides of the protective cover have semi-circular recessed grooves, and pipe sleeves are installed in the grooves. The pipe sleeves of the two parts of the protective cover are joined together to form a ring structure, and the pipes pass through the pipe sleeves.

[0018] The present invention provides a live, sparkless online pipe cutting device for heat transfer systems. By integrating sparkless ceramic cutting, dual-path freezing and sealing technology, and airtight protection and collection technology, it enables safe and environmentally friendly live cutting and replacement of heat transfer oil pipes without system shutdown or media venting. This completely avoids the huge economic losses caused by shutdown, eliminates the risk of combustion and explosion caused by traditional cutting sparks, and effectively prevents pollution to the environment caused by toxic media leakage. It has significant comprehensive benefits of inherent safety, high efficiency, economy, and environmental protection. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0020] Figure 2 This is a schematic diagram of the disassembled structure of the protective cover of the present invention;

[0021] Figure 3 This is a schematic diagram of the internal structure of the protective cover of the present invention;

[0022] Figure 4 This is a schematic diagram of the cutting unit of the present invention;

[0023] Figure 5 This is a schematic diagram showing the disassembled structure of the fixed rail and the movable ring of the toothed ring in this invention;

[0024] Figure 6 This is a schematic diagram of the installation position of the pipe sleeve of the present invention.

[0025] In the diagram: 1. Protective cover; 11. Receiving tray; 12. Exhaust pipe; 13. Slot; 14. Pipe sleeve; 2. Cutting unit; 21. Fixed rail; 22. Gear ring; 23. Drive motor; 24. Gear; 25. Threaded fixing clamp; 26. Electric slide rail; 27. Blade holder; 28. Ceramic cutting blade; 3. Dual refrigeration compressor; 4. Spring-loaded telescopic refrigeration coil; 5. Controller. Detailed Implementation

[0026] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0027] Example 1:

[0028] like Figure 1-6 As shown, this invention discloses a pressurized online sparkless pipe cutting device for a heat conduction system, comprising:

[0029] Protective cover 1 is installed on the outer wall of the pipe cutting point for cutting protection;

[0030] Cutting unit 2, located inside protective cover 1, is used for cutting pipes;

[0031] Explosion-proof refrigeration unit, including:

[0032] Spring-loaded telescopic refrigeration coil 4 is wound around both ends of the cut-off section of the pipe.

[0033] Dual refrigeration compressors 3 are connected to spring-loaded telescopic refrigeration coils 4 via pipes for supplying refrigerant to the spring-loaded telescopic refrigeration coils 4;

[0034] Controller 5 is used to control the coordinated operation of cutting unit 2 and explosion-proof freezing unit.

[0035] The protective cover 1 consists of two parts spliced ​​together and fitted onto the outer wall of the pipe. An exhaust pipe 12 is provided on the protective cover 1 to discharge the gas inside the pipe. Semi-circular recessed grooves 13 are provided on the side walls of both parts of the protective cover 1, and pipe sleeves 14 are provided on the grooves 13. The pipe sleeves 14 of the two parts of the protective cover 1 are joined together to form a ring structure, and the pipe passes through the pipe sleeves 14.

[0036] The protective cover 1 can be composed of two parts made of transparent acrylic material, joined together by bolts or other methods. A groove 13 is provided at the joint of the two parts of the protective cover 1. A pipe sleeve 14 is installed on the groove 13 according to the actual pipe size. When the two parts of the protective cover 1 are joined on the pipe, the pipe passes through the pipe sleeve 14, and the inner diameter of the pipe sleeve 14 matches the actual outer diameter of the pipe. The protective cover 1 is fitted onto the part of the pipe that needs to be cut. An exhaust pipe 12 is provided on the protective cover 1, which can be connected to a boiler for the recovery and reuse of gas. A sealing strip can be installed at the joint of the two parts of the protective cover 1 to seal the joint and prevent gas leakage from the pipe, making it safer and more reliable. Alternatively, a valve pipe can be installed on the protective cover 1, through which nitrogen gas can be introduced into the protective cover 1 for protection.

[0037] The protective cover 1 ensures that sparks are contained inside the cutting unit 2 when it cuts the pipe, preventing any safety hazards to the outside.

[0038] The cutting unit 2 includes a circular fixed rail 21, on which at least three threaded fixing clamps 25 are evenly arranged. The threaded fixing clamps 25 are threadedly connected to the fixed rail 21. A toothed ring movable ring 22 is rotatably connected to the inner wall of the fixed rail 21. An electric slide rail 26 is radially fixedly installed on the side wall of the toothed ring movable ring 22. A blade holder 27 is provided on the electric slide rail 26. A ceramic cutting blade 28 is fixed on the blade holder 27, and the cutting edges of all ceramic cutting blades 28 are in the same radial plane. A drive motor 23 is fixedly installed on the fixed rail 21. The output end of the drive motor 23 is provided with a gear 24 that meshes with the toothed ring movable ring 22. The controller 5 is electrically connected to the drive motor 23 and the electric slide rail 26.

[0039] The fixed rail 21 and the toothed ring movable ring 22 are both composed of two semi-circular structures fixed together by bolts.

[0040] Both the fixed rail 21 and the toothed ring 22 are composed of two semi-circular structures, allowing them to be fitted onto the pipe. The fixed rail 21 is supported on the pipe by threaded fixing clamps 25, of which three are typically used. A fixing block can be installed at the end of the threaded fixing clamp 25 to hold the pipe in place. The threaded fixing clamp 25 and the fixing block are rotatably connected, allowing only rotation without axial displacement. A hexagonal block is installed at the other end of the threaded fixing clamp 25 to engage with a wrench for rotation, thus fixing the fixed rail 21 to the pipe. The toothed ring 22 is located inside the fixed rail 21 and rotates coaxially with it. One side of the toothed ring 22 is rotatably connected to the inner wall of the fixed rail 21, allowing free rotation. The outer wall of the other side of the toothed ring 22 has a toothed ring that meshes with the gear 24 on the drive motor 23 on the fixed rail 21. The gear 24 of the drive motor 23 drives the movable ring 22 of the gear ring to rotate inside the fixed rail 21. An electric slide rail 26, i.e., a linear slide rail, is radially arranged on the side wall of the movable ring 22. A cutter holder 27 is mounted on the electric slide rail 26, and a ceramic cutting blade 28 is mounted on the cutter holder 27. To maintain stability during pipe cutting, at least two electric slide rails 26 are used, and they are evenly spaced. The electric slide rail 26 drives the cutter holder 27, thereby driving the feed of the ceramic cutting blade 28. Using a ceramic cutting blade, no sparks are generated when cutting the pipe, reducing the risk of deflagration. Furthermore, the ceramic cutting blade 28 has high hardness and is wear-resistant. The power supply for the electric slide rail 26 can utilize existing known conductive slip ring technology.

[0041] A receiving tray 11 is slidably disposed at the lower end of the interior of the protective cover 1, with one end of the receiving tray 11 extending to the outside of the protective cover 1 in the sliding direction. The receiving tray 11 is inserted inward from the outside of the protective cover 1 in a drawer-like manner, and the receiving tray 11 is located directly below the cutting unit 2. During the actual cutting process, solid material inside the pipe will fall and can be collected in the receiving tray 11.

[0042] The number of spring-loaded telescopic refrigeration coils 4 at both ends of the pipe cut-off point is divided into two, and both are connected in parallel to the dual refrigeration compressors 3.

[0043] When it is necessary to cut off the pipes on both sides of the valve, a spring-loaded telescopic refrigeration coil 4 is fitted onto the outside of the area to be cut. The spring-loaded telescopic refrigeration coil 4 is a spiral coil that can be wound around the pipe and connected to the dual refrigeration compressor 3. The dual refrigeration compressor 3 provides refrigerant to the spring-loaded telescopic refrigeration coil 4. As the refrigerant continuously circulates into the spring-loaded telescopic refrigeration coil 4, it cools the biphenyl-diphenyl ether inside the pipe, causing it to solidify. When the pipe is cut by the cutting unit 2, there will be no significant leakage of biphenyl-diphenyl ether, ensuring safety and reliability. The spring-loaded telescopic refrigeration coil 4 is a telescopic spiral coil and is a commercially available product. The dual refrigeration compressor 3 is also a commercially available product, as those skilled in the art should know; its specific structure will not be described in detail. To ensure the freezing effect, two spring-loaded telescopic refrigeration coils 4 can be used at each end of the pipe for dual cooling. These two coils are connected in parallel and do not interfere with each other, achieving a more stable and reliable freezing of the biphenyl-diphenyl ether inside the pipe.

[0044] The controller 5 controls the dual refrigeration compressor 3, and also controls the drive motor 23 to drive the gear ring movable ring 22 to rotate at a constant speed. Simultaneously, it controls the feed speed of the electric slide rail 26 to the ceramic cutting blade 28 to ensure stable cutting of the pipe. The electric slide rail 26 is also a commercially available product; its specific structure will not be described in detail here.

[0045] Specific cutting operation process:

[0046] Installation phase:

[0047] First, the two semicircular rings of the toothed ring movable ring 22 are fitted onto the outer wall of the pipe and fixed with bolts to form the toothed ring movable ring 22. Then, the two semicircular rings of the fixed rail 21 are fitted onto the outer wall of the toothed ring movable ring 22 and fixed with bolts. Rotate the multiple threaded fixing clamps 25 so that their ends abut against the outer wall of the pipe, thereby limiting the fixed rail 21 to the pipe. During the limiting process, control the axis of the fixed rail 21 and the toothed ring movable ring 22, preferably coinciding with the axis of the pipe.

[0048] Adjust the position of the electric slide rail 26 on the toothed ring 22 and make the ceramic cutter 28 contact the outer wall of the pipe.

[0049] Next, the pipe sleeve 14 that matches the pipe is inserted into the slot 13 of the protective cover 1, and the two parts of the protective cover 1 are attached to the pipe cutting point. The protective cover 1 completely covers the entire cutting unit 2, so that the protective cover 1 and the exhaust pipe 12 are closed. The pipe sleeve 14 is fitted onto the outer wall of the pipe for sealing. The receiving plate 11 is inserted into the protective cover 1.

[0050] Wrap the spring-loaded telescopic refrigeration coil 4 around both ends of the cut-off section of the pipe, with at least two coils wrapped around each section, and then connect the two ends of the spring-loaded telescopic refrigeration coil 4 to the output and input ends of the dual refrigeration compressor 3, respectively.

[0051] Cryo-plugging:

[0052] Start the dual refrigeration compressor 3. The dual refrigeration compressor 3 delivers refrigerant into the spring-type telescopic refrigeration coil 4, causing the internal temperature before and after the cut to drop below 14°C, forming an ice block.

[0053] Cutting stage:

[0054] Controller 5 starts drive motor 23, and drive motor 23 drives the movable ring gear 22 to rotate at 150 rpm through gear 24;

[0055] The toothed ring 22 drives the electric slide rail 26 to rotate, and the electric slide rail 26 drives the ceramic cutting blade 28 to surround the outside of the pipe through the blade holder 27.

[0056] The electric slide rail 26 advances at a feed speed of 0.01 mm / revolution, simultaneously injecting 99.99% nitrogen into the protective cover 11. The ceramic cutting blade 28 cuts the pipe. If the pipe material has high strength, cooling water can be provided. For example, a water pipe can be installed on the protective cover 1, aligned with the cutting point, and cooling water can be poured onto the cutting point to cool it down. This method is a common cutting method and will not be described in detail here.

[0057] Collection and processing:

[0058] The gas generated during cutting is transported to the boiler for calcination through the exhaust pipe 12 at the top of the protective cover 1 to reduce pollution, while solids and liquids fall into the receiving tray 11 for recycling.

[0059] Security control implementation:

[0060] Overload protection mechanism:

[0061] Controller 5 monitors the operating current of drive motor 23 in real time via a current sensor;

[0062] When the current value exceeds the rated value, the controller 5 automatically reduces the feed speed of the electric slide rail 26.

[0063] Emergency stop function:

[0064] A red emergency stop button is provided on the controller 5. When the emergency stop button is pressed, the power supply to the drive motor 23 and the electric slide rail 26 is immediately cut off.

[0065] Automatic feed control:

[0066] The controller 5 controls the feed amount of the electric slide rail 26 through encoder feedback;

[0067] For each revolution of the ceramic cutting blade 28, the controller 5 automatically controls the electric slide rail 26 to feed at a rate of 0.01mm (adjustable).

[0068] Enhanced cryogenic protection:

[0069] In the event of an emergency stop, the dual refrigeration compressors 3 automatically switch to maximum power mode;

[0070] The spring-loaded telescopic refrigeration coil 4 quickly reduces the temperature at both ends of the cutting area.

[0071] This invention integrates a protective cover 1, a cutting unit 2, dual refrigeration compressors 3, and a controller 5 to achieve the function of online, spark-free cutting and valve replacement under pressure in a heat transfer system. The cutting operation is completed within the protective cover 1, using ceramic blades to prevent sparks. The dual refrigeration compressors 3, in conjunction with spring-loaded telescopic refrigeration coils 4, provide low-temperature sealing to the cutting area. The controller 5 uses variable frequency speed control and temperature feedback to coordinate the cutting feed and refrigeration effect. Emergency stop and overload protection ensure operational safety, and the cutting media is recycled and treated. The entire process allows valve replacement to be completed without system shutdown.

[0072] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0073] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the interaction relationship between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0074] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0075] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simplification, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A pressurized online sparkless pipe cutting device for a heat conduction system, characterized in that, include: A protective cover, installed on the outer wall of the pipe cutting area, is used for cutting protection; The cutting unit, housed within a protective cover, is used for cutting pipes; Explosion-proof refrigeration unit, including: Spring-loaded telescopic refrigeration coils are wound around both ends of the cut-off section of the pipe. Dual refrigeration compressors are connected to spring-loaded telescopic refrigeration coils via pipes to supply refrigerant to the coils. The controller is used to control the coordinated operation of the cutting unit and the explosion-proof freezing unit.

2. The heat conduction system pressurized online sparkless pipe cutting device according to claim 1, characterized in that, The cutting unit includes a circular fixed rail with at least three threaded clamping rods evenly spaced on it. These threaded clamping rods are threadedly connected to the fixed rail. A toothed ring is rotatably connected to the inner wall of the fixed rail. An electric slide rail is radially fixed to the side wall of the toothed ring. A blade holder is mounted on the electric slide rail, and ceramic cutting blades are fixed on the blade holder, with all the blade edges of the ceramic cutting blades on the same radial plane. A drive motor is fixedly mounted on the fixed rail, and the output end of the drive motor has a gear that meshes with the toothed ring. The controller is electrically connected to the drive motor and the electric slide rail.

3. The heat conduction system pressurized online sparkless pipe cutting device according to claim 2, characterized in that, The fixed rail and the movable toothed ring are both composed of two semi-circular structures fixed together by bolts.

4. The heat conduction system pressurized online sparkless pipe cutting device according to claim 1, characterized in that, The protective cover consists of two parts spliced ​​together and fitted onto the outer wall of the pipe. An exhaust pipe is installed on the protective cover to discharge the gas inside the pipe.

5. The pressurized online sparkless pipe cutting device for a heat conduction system according to claim 1, characterized in that, A mooring plate is slidably installed at the lower end of the inside of the protective cover, with one end of the mooring plate extending to the outside of the protective cover in the sliding direction.

6. The pressurized online sparkless pipe cutting device for a heat conduction system according to claim 1, characterized in that, The number of spring-loaded telescopic refrigeration coils at both ends of the pipe cut-off point is divided into two, and both are connected in parallel to the dual refrigeration compressor.

7. A pressurized online sparkless pipe cutting device for a heat conduction system according to claim 4, characterized in that, Both sides of the protective cover have semi-circular recessed grooves, and pipe sleeves are installed in the grooves. The pipe sleeves of the two parts of the protective cover are joined together to form a ring structure, and the pipes pass through the pipe sleeves.

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