Valve and electric actuator detection system and method

Abstract

The invention discloses a valve and electric actuator detection system in the technical field of valve testing, which comprises a comprehensive detector, the comprehensive detector is electrically connected with an electric actuator, and the electric actuator is connected with a tested valve; the comprehensive detector comprises a power supply module, a voltage regulating module, a display module, a control panel and a signal receiving module; the voltage regulating module is used for regulating the output voltage; the display module is used for displaying a voltage value, a torque value and valve opening and closing instructions; the control panel is used for regulating and controlling the working states of the valve and the electric actuator; the electric actuator is provided with a remote control module, a near control module, a torque percentage setting module, a full-opening and full-closing position setting module, a numerical value display module and a signal feedback module. The signal feedback module is electrically connected with the signal receiving module; multiple test items of the valve can be integrated into a set of complete system, the test efficiency and the test safety are improved, and the labor cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of valve testing technology, and in particular to a valve and electric actuator testing system and method. Background Technology

[0002] In the design and development of new valves, it is necessary to verify the valve's switching torque, sealing performance, and the number of times components are switched (after completing the number of switches in the experimental outline, the valve is disassembled and the components are inspected), as well as whether the electric actuator works normally under voltage fluctuations. This comprehensive testing instrument can adopt a remote control + camera monitoring operation mode to fully ensure the safety of operators and testers. Previously used methods such as manual electric actuators and dedicated torque testers have problems such as long valve switching time, low efficiency, large number of personnel required, and poor safety. Summary of the Invention

[0003] To overcome the shortcomings of existing technologies, the technical problem to be solved by this invention is: how to improve the efficiency and safety of comprehensive valve testing.

[0004] The technical solution adopted by this invention to solve its technical problem is: A valve and electric actuator testing system includes a comprehensive testing instrument, which is electrically connected to an electric actuator, and the electric actuator is connected to the valve under test. The integrated testing instrument includes a power supply module, a voltage regulation module, a display module, a control panel, and a signal receiving module; the voltage regulation module is used to adjust the output voltage; the display module is used to display voltage values, torque values, and valve open / close indicators; the control panel is used to regulate the working status of the valve and the electric actuator. The electric actuator is equipped with a remote control module, a local control module, a torque percentage setting module, a fully open and fully closed position setting module, a numerical display module, and a signal feedback module. The signal feedback module is electrically connected to the signal receiving module.

[0005] Furthermore, the voltage regulating module includes an autotransformer, the power value of which is greater than 1.5 times the power value of the electric actuator.

[0006] Furthermore, the electronic circuits of each module are connected via aviation connectors.

[0007] This invention also proposes a comprehensive testing method for valves and electric actuators, employing the aforementioned valve and electric actuator testing system, including the following steps: S1: Test whether the voltage output of the integrated tester is normal; S2: Connect the integrated testing instrument, electric actuator, and valve under test via electronic circuitry; S3: Select the electric actuator to the local control mode and adjust the percentage of the electric actuator's on / off position to match the fully open and fully closed positions of the valve being tested; S4: Adjust the electric actuator to remote control mode. The electric actuator will drive the valve under test to fully open and close multiple times under no-load conditions after receiving the instruction from the integrated tester. During the opening and closing process, observe the display window of the electric actuator, whether there is any abnormality in the action of the valve under test, and whether each control button, feedback signal indicator and digital counter are working properly. S5: Operate the integrated testing instrument to control the valve under test to be fully closed, and test the sealing performance of the valve under test by pressurizing to the preset value; S6: After testing the sealing performance and releasing the pressure, retrieve the percentage value of the electric actuator to calculate the torque value, and compare the measured torque value with the standard torque value; S7: Operate the autotransformer to adjust the output voltage up or down, and check whether the electric actuator operates abnormally under voltage fluctuation conditions.

[0008] Furthermore, in step S1, the voltage testing process is as follows: the power input plug is connected to the workshop's 380V five-wire power supply, the power switch is turned on, and the voltage display shows the current mains voltage. At this time, the voltage value is observed during the process by adjusting the autotransformer, and the voltage is reduced or increased to the value required for the experiment.

[0009] Furthermore, after the voltage test is completed, turn off the power and connect the power supply to the electric actuator, then observe the LED window of the electric actuator for any abnormalities.

[0010] Furthermore, in step S5, the sealing performance test process is as follows: the integrated testing instrument is placed at a sufficiently safe distance, the remote control system of the integrated testing instrument is operated to set the valve under test to the fully closed state, and the valve under test is pressurized to the specified value using a special pressure testing device to test the sealing performance.

[0011] Furthermore, steps S3-S6 form a test cycle. After repeating the test cycle a preset number of times, the test is stopped to check for any abnormalities in the electric actuator and the valve under test.

[0012] Furthermore, if no abnormalities are found during the test, multiple test cycles will continue until the valve is opened and closed a preset number of times. Then, the test will be stopped, and the valve under test will be disassembled to check the condition of the valve components.

[0013] The beneficial effects of this invention are: The technical solution proposed in this application provides actual verification of the switching torque value of the valve under full differential pressure, the number of switching cycles that valve components can withstand, and whether the electric actuator works normally under voltage fluctuations. The application also provides a complete integrated testing and control system that can integrate multiple valve testing items into a complete system, improving testing efficiency and safety, and reducing labor costs. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the coupling transformer wiring circuit of the present invention; The components in the diagram are labeled as follows: 1-Comprehensive testing instrument, 2-Electric actuator, 3-Valve under test, 4-Autotransformer, 5-Digital counter, 6-Digital input voltmeter, 7-Digital output voltmeter, 8-Control panel, 9-Signal feedback plug, 10-Remote control plug, 11-Power output plug, 12-Power input plug. Detailed Implementation

[0015] The invention will be further described below with reference to the accompanying drawings.

[0016] like Figure 1 As shown in the figure, this application proposes a valve and electric actuator testing system, including a comprehensive testing instrument 1, which is electrically connected to an electric actuator 2, and the electric actuator 2 is connected to a valve 3 under test. The comprehensive testing instrument 1 includes a power supply module, a voltage regulation module, a display module, a control panel 8, and a signal receiving module. The voltage regulation module is used to adjust the output voltage. The display module is used to display voltage values, torque values, and valve open / close indicators. The control panel 8 is used to regulate the working status of the valve and the electric actuator 2. The electric actuator 2 is equipped with a remote control module, a local control module, a torque percentage setting module, a fully open and fully closed position setting module, a numerical display module, and a signal feedback module. The signal feedback module is electrically connected to the signal receiving module.

[0017] Specifically, the aforementioned power supply module is an external 380V five-wire power supply for the workshop, which supplies power to the integrated testing instrument 1 and the electric actuator 2. The voltage regulation module regulates the voltage to ensure the adjustment and testing of the input and output voltage of the equipment. The control panel 8 is connected to the electric actuator 2 through electronic circuitry. The electric actuator 2 is electrically connected to the invention's opening and closing control structure. The control buttons on the control panel 8 are used to control the electric actuator 2, test the valve's opening and closing status and the torque of the electric actuator 2. The display module is used to display voltage values, torque values, valve opening and closing indicators to ensure real-time observation and recording of various parameters during testing.

[0018] Furthermore, the electric actuator 2 is equipped with a remote control module and a local control module, which can adjust the control mode. The torque percentage setting module and the fully open and fully closed position setting module can set the torque of the electric actuator 2 and the opening and closing state of the valve 3 under test according to the experimental progress. Moreover, the set state and corresponding parameters can be displayed through the numerical display module.

[0019] The remote valve open, close, and stop button control lines are connected to the terminals of the remote control plug 10, and later connected to the internal remote control terminals of the electric actuator 2 via a control cable. After the valve and actuator are installed and debugged, the remote / local control selection knob is turned to remote control, and the actuator operation is then completely remotely controlled by the integrated testing instrument 1.

[0020] The integrated testing instrument 1 connects the valve open, valve close, and stop feedback signal indicator lights to the signal feedback plug 9 terminal, and the other end connects to the valve fully open, valve fully closed, and stop control button control circuit inside the electric actuator 2 via the signal feedback cable. The terminals of each feedback contact, the valve fully open and fully closed contacts are connected to the digital display counter 5 and the signal terminal, which can record the number of switching times in real time through the digital display counter 5.

[0021] First, it should be stated that the actual verification of the switching torque value of the valve 3 under full differential pressure, the number of switching cycles that the valve components can withstand, and whether the electric actuator 2 works normally under voltage fluctuations is carried out. The provided complete integrated testing and control system can integrate multiple valve test items into a complete system, improve testing efficiency and safety, and reduce labor costs.

[0022] Specifically, the voltage regulating module includes an autotransformer 4, the power value of which is greater than 1.5 times the power value of the electric actuator 2, ensuring that the maximum voltage of the electric actuator 2 can be reached by adjusting the voltage, thus obtaining comprehensive voltage test data; and in order to ensure the safety of the equipment and the stability of the electrical connection, the electronic circuits of each module are connected by aviation plugs.

[0023] This embodiment also proposes a comprehensive testing method for valves and electric actuators, including the following steps. S1: Test whether the voltage output of the integrated testing instrument 1 is normal; the integrated testing instrument 1 includes two sets of terminals of the autotransformer 4 inside the control cabinet, which are connected to the input power and output power aviation plugs respectively, and connected in parallel to the digital display input voltmeter 6 and the digital display output voltmeter 7 respectively; the power input plug 12 is connected to the workshop's 380V five-wire power supply, and the power switch is turned on. The digital display input voltmeter 6 displays the current mains voltage. At this time, the autotransformer 4 can be manually adjusted (according to the arrow on the control cabinet panel, turning the handwheel clockwise increases the voltage, and counterclockwise decreases the voltage). During the process, observe the number displayed on the digital display output voltmeter 7, and lower or raise the voltage to the value required for the experiment; turn off the power and connect the power output plug 11 to the relevant terminals of the electric actuator 2, and observe whether there is any abnormality in the display module of the electric actuator 2; test whether there is any abnormality in the voltage adjustment input state, output state and electric actuator 2 under low voltage and high voltage conditions through the double-digit process; if there is any abnormality, further debugging and repair are required, and subsequent tests can be carried out after the test is normal.

[0024] S2: Connect the integrated testing instrument 1, the electric actuator 2, and the valve under test 3 via electronic circuitry; connect the relevant control terminals of the integrated testing instrument 1 and the electric actuator 2 via the remote control plug 10, and connect the signal feedback plug 9 of the integrated testing instrument 1 to the corresponding signal feedback terminal of the electric actuator 2; specifically, as follows... Figure 2 As shown, L1, L2, L3, N, and E wires are connected at one end to the input cable plug terminal inside the electrical cabinet of the integrated testing instrument 1, and at the other end to the input terminals A, B, C, N, and E of the autotransformer 4 inside the electrical control cabinet. The output terminals a, b, c, N, and E are connected to the power output plug terminal 11 on the control cabinet. The input and output terminals are then connected in parallel to the digital input voltmeter 6 and the digital output voltmeter 7, respectively.

[0025] S3: Select and adjust electric actuator 2 to local control mode, and adjust the percentage of the electric actuator 2's on / off position to match the fully open and fully closed positions of the valve under test 3. Specifically, turn on the power switch, and according to the electric actuator 2 installation and commissioning manual, turn the electric actuator 2 selection knob to local control mode, and adjust the percentage of the electric actuator 2's on / off position to match the fully open and fully closed positions of the valve under test. Based on the preset torque value of the valve under test, set the percentage of the electric actuator 2's valve on / off torque value to be basically consistent with the torque value of the valve under test.

[0026] S4: Adjust the electric actuator 2 to remote control mode. The electric actuator 2 receives the instruction from the integrated tester 1 to drive the valve under test 3 to fully open and close multiple times under no-load conditions. During the opening and closing process, observe the display window of the electric actuator 2, whether the valve under test 3 is moving abnormally, and whether each control button, feedback signal indicator and digital counter 5 is working properly. In this embodiment, it is run under no-load for 6 times (the voltage is adjusted up and down 3 times respectively). Observe whether the actuator and valve opening and closing are abnormal, and whether each button control and display screen are sensitive and accurate.

[0027] Specifically, turn the selector knob of electric actuator 2 to remote control mode, operate the valve control button on the panel of the integrated testing instrument 1, and drive the tested valve to fully open and fully close two to three times under no-load conditions. During the opening and closing process, observe whether there is a fault display in the LED window of electric actuator 2 (the LED window of electric actuator 2 can be remotely monitored with a camera during the valve pressure test), whether the tested valve moves abnormally, and whether all control buttons, feedback signal indicator lights, digital counter 5, etc. are working properly. If there are no abnormalities during the opening and closing process, you can proceed to the next step according to the experimental outline; if there are abnormalities, further testing and debugging of the equipment are required.

[0028] S5: Operate the integrated testing instrument 1 to control the valve under test 3 to be fully closed, and test the sealing performance of the valve under test 3 by pressurizing it to the preset value; install the electric actuator 2 and the valve under test 3 in a dedicated test site and set up safety warning signs; place the integrated testing instrument 1 at a safe distance, operate the remote control system of the integrated testing instrument 1 to put the valve in the fully closed state, and pressurize the valve to the specified value with a dedicated pressure testing device according to the experimental outline to test its sealing performance. After passing the test, remotely control the valve to open.

[0029] S6: After testing the sealing performance and releasing the pressure, retrieve the 2% digital value of the electric actuator to calculate the torque value, compare the measured torque value with the standard torque value, record the relevant values, and analyze the range of numerical deviation.

[0030] Furthermore, in order to improve the accuracy of the test results, a test cycle is formed in steps S3-S6. After repeating the test cycle a preset number of times, the test is stopped to check whether there are any abnormalities in the electric actuator 2 and the valve under test. If there are no abnormalities, the operation continues until the number of valve opening and closing times recorded by the digital counter 5 reaches the preset number. Then, the valve is disassembled to check the condition of the valve components.

[0031] S7: Operate the autotransformer 4 to adjust the output voltage up or down, check whether the electric actuator 2 operates abnormally under voltage fluctuation, test whether the electric actuator 2 malfunctions under voltage fluctuation, and ensure the reliability of the electric actuator 2.

[0032] In summary, this invention proposes a valve and electric actuator testing system and method. It tests the switching torque value of the valve 3 under full differential pressure, the number of switching cycles that valve components can withstand, and whether the electric actuator 2 operates normally under voltage fluctuations, providing practical verification. The system connects to the workshop power supply via an input power cable plug, and the output power cable plug connects to the terminals of the electric actuator 2. Each remote control cable plug is connected to the control terminals of the electric actuator 2, and the feedback signal cable plug is connected to the signal feedback terminals of the electric actuator 2. The system and method proposed in this invention are simple to operate, easy to understand, and allow for ultra-long-distance control. The safety distance can be appropriately increased based on the safety of the tested product to fully ensure the safety of personnel and equipment. It is convenient to use and suitable for large-scale adoption by valve manufacturers.

Claims

1. A valve and electric actuator testing system, characterized in that, Includes a comprehensive testing instrument (1), which is electrically connected to an electric actuator (2), and the electric actuator (2) is connected to the valve to be tested (3); The integrated testing instrument (1) includes a power supply module, a voltage regulation module, a display module, a control panel (8), and a signal receiving module; the voltage regulation module is used to adjust the output voltage; the display module is used to display voltage values, torque values, and valve open / close indicators; the control panel (8) is used to regulate the working status of the valve and the electric actuator (2); The electric actuator (2) is equipped with a remote control module, a local control module, a torque percentage setting module, a fully open and fully closed position setting module, a numerical display module and a signal feedback module; The signal feedback module is electrically connected to the signal receiving module.

2. The valve and electric actuator detection system according to claim 1, characterized in that, The voltage regulating module includes an autotransformer (4), the power value of which is greater than 1.5 times the power value of the electric actuator (2).

3. The valve and electric actuator detection system according to claim 1, characterized in that, The electronic circuits of each module are connected via aviation connectors.

4. A comprehensive testing method for valves and electric actuators, employing the valve and electric actuator testing system as described in any one of claims 1-3, characterized in that, Includes the following steps, S1: Test whether the voltage output of the integrated testing instrument (1) is normal; S2: Connect the integrated testing instrument (1), electric actuator (2) and the valve under test (3) through electronic circuitry; S3: Select the electric actuator (2) to the local control mode and adjust the percentage of the switch position of the electric actuator (2) to be consistent with the fully open and fully closed positions of the valve (3) under test; S4: Adjust the electric actuator (2) to the remote control mode. The electric actuator (2) receives the instruction from the integrated tester (1) to drive the valve under test (3) to fully open and close multiple times under no-load conditions. During the opening and closing process, observe whether the display window of the electric actuator (2), the action of the valve under test (3) is abnormal, and whether each control button, feedback signal indicator and digital counter (5) are working normally. S5: Operate the integrated testing instrument (1) to control the valve (3) under test to be fully closed, and test the sealing performance of the valve (3) under test by pressurizing to the preset value; S6: After testing the sealing performance and releasing the pressure, retrieve the percentage number of the electric actuator (2) to calculate the torque value, and compare the measured torque value with the standard torque value; S7: Operate the autotransformer (4) to adjust the output voltage up or down, and check whether the electric actuator (2) has any abnormal operation under voltage fluctuation conditions.

5. The comprehensive testing method for valves and electric actuators according to claim 4, characterized in that, In step S1, the voltage test process is as follows: the power input plug (12) is connected to the workshop 380V five-wire power supply, the power switch is turned on, the voltage display shows the current mains voltage, at this time the voltage value is observed by adjusting the autotransformer (4) during the process, and the voltage is reduced or increased to the value required for the experiment.

6. The comprehensive testing method for valves and electric actuators according to claim 5, characterized in that, After the voltage test is completed, turn off the power and connect the power supply to the electric actuator (2), and observe whether there is any abnormality in the LED window display of the electric actuator (2).

7. The comprehensive testing method for valves and electric actuators according to claim 4, characterized in that, In step S5, the sealing performance test process is as follows: place the integrated testing instrument (1) at a safe distance, operate the remote control system of the integrated testing instrument (1) to set the valve (3) under test to the fully closed state, and use a special pressure testing device to pressurize the valve (3) under test to the specified value to test the sealing performance.

8. The comprehensive testing method for valves and electric actuators according to claim 4, characterized in that, Steps S3-S6 form a test cycle. After repeating the test cycle a preset number of times, stop and check whether there are any abnormalities in the electric actuator (2) and the valve under test.

9. The comprehensive testing method for valves and electric actuators according to claim 8, characterized in that, If no abnormalities are found during the test, continue to perform multiple test cycles until the number of valve opening and closing times reaches the preset number, then stop the test and disassemble the valve under test (3) to check the condition of the valve components.

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