Flange leaking stoppage composite leaking stoppage structure and method of embedded gas monitoring sensor

Abstract

The invention provides a flange leaking stoppage composite leaking stoppage structure and method of an embedded gas monitoring sensor, and aims to solve the problem of leakage at a flange joint. Through the combination of real-time monitoring and a multi-layer composite leaking stoppage structure, efficient and stable leaking stoppage of gas leakage at the flange connecting position is achieved, and the safety and reliability of industrial production are improved. The gas leakage condition at the flange joint is monitored in real time through the embedded gas monitoring sensor, and when the sensor detects that the concentration of leaked gas exceeds a preset threshold value, the wired gas monitoring alarm indicator sends out an alarm signal. The invention further comprises a multi-layer composite leaking stoppage structure which sequentially comprises a joint filling sealant layer, a wet-process glass fiber composite material layer, a preformed carbon fiber composite material layer and a high-strength pouring material layer. The method has the characteristics of real-time monitoring, timely alarming, multi-layer leaking stoppage and the like, is simple and convenient to operate, is suitable for various flange joints, and has important practical value. The efficient and stable flange leaking stoppage effect is achieved through combination of real-time monitoring and a multi-layer composite leaking stoppage structure. Compared with a traditional leaking stoppage method, the method has the following advantages that the leakage problem can be found in time through the real-time monitoring function; the stability and durability of leaking stoppage are improved through the multi-layer composite leaking stoppage structure; and the device is suitable for various flange joints. Therefore, the method has a wide application prospect and an important practical value.

Description

Technical Field

[0001] This invention relates to pipeline flange connection technology, and in particular to a composite leak-sealing structure and method with real-time monitoring function. Background Technology

[0002] In industrial production, flange connections are a crucial component of fluid transmission systems. However, due to factors such as long-term use, mechanical vibration, and temperature variations, flange connections are prone to leakage. Existing leak-sealing methods often rely on periodic inspections and maintenance, lacking real-time monitoring and early warning mechanisms, making it difficult to detect and address leaks promptly. Therefore, developing a composite leak-sealing structure and method with real-time monitoring capabilities is of paramount importance.

[0003] Invention Patent Content

[0004] The purpose of this invention is to provide a composite leak-sealing structure and method for flange leak sealing with an embedded gas monitoring sensor, which aims to monitor gas leakage at the flange connection in real time and use multiple layers of leak-sealing materials for efficient and stable leak sealing.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A flange-based composite leak-sealing structure with an embedded gas monitoring sensor includes a flange plate with an embedded gas monitoring acquisition port. A gas monitoring sensor is installed inside the acquisition port and connected to a wired gas monitoring alarm indicator. When the sensor detects that the concentration of leaked gas exceeds a preset threshold, the wired gas monitoring alarm indicator will issue an alarm signal.

[0007] In addition, the composite sealing structure also includes multiple layers of sealing materials, namely: a sealant layer, a wet-process glass fiber composite material layer, a preformed carbon fiber composite material layer, and a high-strength injection material layer.

[0008] The present invention also provides a method for flange sealing using the above-mentioned composite sealing structure, comprising the following steps:

[0009] (1) Real-time monitoring of gas leakage at flange connections using embedded gas monitoring sensors;

[0010] (2) Once the sensor detects that the concentration of leaked gas exceeds the preset threshold, the wired gas monitoring alarm indicator will issue an alarm signal.

[0011] (3) After receiving the alarm signal, use a high-pressure glue gun to inject sealant for initial sealing;

[0012] (4) Install wet glass fiber composite material, preformed carbon fiber composite material and high-strength injection material in sequence to form a multi-layer composite sealing structure. Attached Figure Description

[0013] To more clearly illustrate the technical solutions of the embodiments of this invention, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0014] Figure 1 This exhibit showcases the installation location of the embedded gas monitoring sensor, the structure of the multi-layered sealing material, and the layout of the entire composite sealing structure. It includes: ① pipe, ② flange, ③ flange fastening bolts, ④ embedded gas monitoring acquisition port, ⑤ sealant, ⑥ embedded gas monitoring sensor, ⑦ wired gas monitoring alarm indicator, ⑧ bottom injection port for high-pressure caulking gun, ⑨ wet-laid glass fiber composite material, and ⑩ preformed carbon fiber composite material. High-strength grouting material High-pressure caulking gun. The following is a detailed explanation of the entire composite sealing structure:

[0015] Pipeline (①): Responsible for the transmission of fluids.

[0016] Flange (②): Leakage has occurred on its sealing surface.

[0017] Flange fastening screws (③): used to fasten the flange plate.

[0018] Embedded gas monitoring and sampling port (④): Embedded in the flange plate, used to collect samples of leaked gas.

[0019] Crack sealant (⑤): As the first layer of sealing material, it is used to initially fill the gaps between the flanges.

[0020] Embedded gas monitoring sensor (⑥): capable of sensing the concentration of leaked gas in real time.

[0021] Wired gas monitoring alarm indicator (⑦): Connects to a gas monitoring sensor to display gas concentration and issue an alarm signal.

[0022] The bottom nozzle (⑧) for high-pressure caulking guns: facilitates the injection of more sealant when needed.

[0023] Wet-process glass fiber composite material (⑨): As a second-layer sealing material, it has excellent tensile properties and can withstand axial and circumferential tensile forces.

[0024] Preformed carbon fiber composite material (⑩): As the fourth layer of sealing material, it also bears axial and circumferential tensile forces, enhancing the overall strength of the structure.

[0025] High-strength grout After the pre-formed carbon fiber composite material is installed, it is poured on-site as the third layer of sealing material, mainly bearing the axial and circumferential pressure.

[0026] High-pressure glue gun Used for manual high-pressure injection of sealant to ensure a tight sealant filling.

[0027] Figure 2 A side view of the composite leak-sealing structure layout. Detailed Implementation

[0028] like Figure 1 As shown, the flange-sealing composite leak-sealing structure of the present invention includes a flange plate ②, on which an embedded gas monitoring and acquisition port ④ is provided. A gas monitoring sensor ⑥ is installed inside the acquisition port ④, and the sensor is connected to a wired gas monitoring alarm indicator ⑦. When the sensor ⑥ detects that the concentration of leaked gas exceeds a preset threshold, the wired gas monitoring alarm indicator ⑦ will issue an alarm signal.

[0029] Upon receiving the alarm signal, the operator first used a high-pressure caulking gun to inject sealant (⑤) for initial leak sealing. Then, wet-process glass fiber composite material (⑨), pre-formed carbon fiber composite material (⑩), and high-strength injection mortar were installed sequentially. This forms a multi-layered composite sealing structure.

[0030] By combining real-time monitoring with a multi-layer composite leak-sealing structure, this invention can achieve efficient and stable flange leak-sealing effects, thereby improving the safety and reliability of industrial production.

[0031] In existing flange connection technologies, leaks are prone to occur at flange connections due to factors such as long-term use, mechanical vibration, and temperature changes. Such leaks not only lead to fluid waste but can also pollute the environment and even cause safety accidents. However, traditional leak-sealing methods often rely on regular inspections and maintenance, lacking real-time monitoring and early warning mechanisms, making it difficult to detect and address leaks in a timely manner.

[0032] This invention provides a composite leak-sealing structure and method for flange leak sealing with an embedded gas monitoring sensor. By combining real-time monitoring and a multi-layer composite leak-sealing structure, it solves the problems existing in traditional leak-sealing methods.

[0033] First, this invention features an embedded gas monitoring port on the flange, with a gas monitoring sensor installed inside. This sensor can monitor gas leaks at the flange connection in real time. Once the concentration of leaked gas exceeds a preset threshold, an alarm signal is issued via a wired gas monitoring alarm indicator, thus promptly detecting the leak.

[0034] Secondly, this invention employs a multi-layered composite leak-sealing structure, consisting of a sealant layer, a wet-process glass fiber composite material layer, a pre-formed carbon fiber composite material layer, and a high-strength injection refractory layer. This multi-layered structure ensures the stability and durability of the leak sealing, effectively preventing recurrence of leaks.

[0035] Finally, this invention also provides a method for sealing flange leaks using the aforementioned composite sealing structure. Upon receiving an alarm signal, operators can quickly take measures to seal the leak. First, a high-pressure caulking gun is used to inject sealant for initial sealing. Then, wet-laid glass fiber composite material, pre-formed carbon fiber composite material, and high-strength injection mortar are sequentially installed to form a multi-layer composite sealing structure. This method is simple, fast, and effective, and is suitable for various flange connections.

[0036] Example

[0037] Specific models of embedded gas monitoring sensors: For example, select miniature methane gas monitoring sensors from well-known brands on the market, such as the HTU series from Hanwei Technology Group, the ICM201 series from Suzhou Xinmeixin Electronics, etc.

[0038] Technical parameters: sensitivity is ±2%FS, sampling accuracy is ±1%, and operating temperature is -20℃ to 50℃.

[0039] Installation location: The sensor is installed inside the embedded acquisition port of the flange, ensuring a tight fit with the flange.

[0040] Connection method: The sensor is connected to the gas monitoring alarm indicator via wire to realize real-time monitoring and alarm functions.

[0041] Multi-layer sealing material:

[0042] Crack sealant: Select a high-temperature resistant and corrosion-resistant sealant for initial leak sealing.

[0043] Wet-process glass fiber composites: possessing good toughness and corrosion resistance, used to enhance the stability of leak-sealing structures.

[0044] Preformed carbon fiber composite material: high strength and wear resistance, further improving the leak sealing effect.

[0045] High-strength injection material: high strength after curing, ensuring the durability of the leak-sealing structure.

[0046] Crack sealant: Selected based on its high temperature resistance and corrosion resistance to ensure effective leak sealing in various environments.

[0047] Glass fiber and carbon fiber composites: These materials are chosen because they combine strength and durability, effectively enhancing the stability of the sealing structure.

[0048] High-strength grouting material: Due to its high strength and durability after curing, it can protect the internal structure from external erosion.

[0049] This method is applicable to different types of flange connections and different working conditions because its core principle is universal: real-time monitoring and multi-layer composite leak sealing.

[0050] All materials used have undergone rigorous screening and meet relevant safety standards to ensure stability even under extreme conditions.

[0051] Compared with traditional leak-sealing methods, the composite leak-sealing structure provided by this invention has lower cost and longer-lasting effect, thus having higher cost-effectiveness.

[0052] Materials and equipment:

[0053] Flanges: Standard-sized carbon steel flanges are selected.

[0054] Gas monitoring sensor: Select a high-sensitivity gas leak monitoring sensor that is available on the market.

[0055] Collection port: Custom-designed embedded gas monitoring collection port that matches the flange.

[0056] Sealant: Select a high-temperature resistant and corrosion-resistant sealant.

[0057] Glass fiber composites and carbon fiber composites: Choose mature composite material products on the market.

[0058] High-strength grouting material: grouting material with high strength and good durability after curing is selected.

[0059] High-pressure caulking gun: used for injecting sealant into joints.

[0060] Operating steps:

[0061] (1) Install gas monitoring sensor: Install gas monitoring sensor in the pre-set embedded gas monitoring acquisition port on the flange, and ensure that the sensor is tightly fitted to the flange and there is no gas leakage.

[0062] (2) Connect the alarm indicator: Connect the gas monitoring sensor to the wired gas monitoring alarm indicator to ensure that the alarm indicator can immediately issue an alarm signal when the sensor detects that the concentration of leaked gas exceeds the preset threshold.

[0063] (3) Preliminary sealing: After receiving the alarm signal, quickly use a high-pressure glue gun to inject sealant into the flange connection to perform preliminary sealing.

[0064] (4) Install composite material layer: After the initial sealing, install wet glass fiber composite material layer and preformed carbon fiber composite material layer in sequence to ensure that each layer of material is tightly bonded without bubbles or gaps.

[0065] (5) Injecting high-strength grout: Injecting high-strength grout outside the composite material layer to form a solid outer protective layer, enhancing the stability and durability of the plugging structure.

[0066] (6) Testing and Verification: After the leak sealing operation is completed, a leak test is conducted to ensure that there is no gas leakage at the flange connection. At the same time, the condition of the leak-sealed structure is observed and recorded over a long period of time to verify its stability and durability.

[0067] Experiment and Results

[0068] Through multiple experiments, the flange sealing composite structure and method provided by this invention can monitor and respond quickly to gas leaks at flange connections in real time. In the experiments, when the gas monitoring sensor detects that the concentration of leaking gas exceeds a preset threshold, the alarm indicator immediately issues an alarm signal, reminding operators to take sealing measures. Simultaneously, the multi-layer composite sealing structure exhibits good stability and durability, with no leaks detected during prolonged observation and testing. Compared with existing technologies, this invention offers higher sealing efficiency and better performance.

Claims

1. A flange leak-sealing composite structure for an embedded gas monitoring sensor, characterized in that, It includes a flange with an embedded gas monitoring and acquisition port, into which a gas monitoring sensor is installed.

2. The flange sealing composite structure according to claim 1, characterized in that, The gas monitoring sensor is connected to a wired gas monitoring alarm indicator and is used to issue an alarm signal when the sensor detects that the concentration of leaked gas exceeds a preset threshold.

3. The flange sealing composite structure according to any of the preceding claims, characterized in that, It also includes a multi-layer sealing material, consisting of a sealant layer, a wet-process glass fiber composite material layer, a pre-formed carbon fiber composite material layer, and a high-strength injection material layer.

4. A method for sealing leaks using a flange-sealing composite structure, characterized in that, This includes real-time monitoring of gas leaks at flange connections using embedded gas monitoring sensors.

5. The method according to claim 4, characterized in that, It also includes the step of issuing an alarm signal via a wired gas monitoring alarm indicator when the sensor detects that the concentration of leaked gas exceeds a preset threshold.

6. The method according to claim 4 or 5, characterized in that, It also includes the step of using a high-pressure caulking gun to inject sealant for initial leak sealing after receiving an alarm signal.

7. The method according to claim 6, characterized in that, It also includes the steps of sequentially installing wet-process glass fiber composite material, pre-formed carbon fiber composite material, and injecting high-strength injection material after the initial leak sealing to form a multi-layer composite leak sealing structure.

8. The method according to claim 7, characterized in that, The multi-layer composite sealing structure ensures the stability and durability of the sealing process.

9. A flange sealing system, characterized in that, It includes the flange sealing composite structure as described in any one of claims 1 to 3 and a monitoring system for real-time monitoring and control of the composite structure.

10. The flange sealing system according to claim 9, characterized in that, The monitoring system includes a gas monitoring sensor and a wired gas monitoring alarm indicator. The gas monitoring sensor is installed in the embedded gas monitoring acquisition port of the flange plate to monitor the gas leakage at the flange connection in real time, and issues an alarm signal through the wired gas monitoring alarm indicator when the concentration of leaked gas exceeds a preset threshold.

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