Intelligent control safety valve steam exhaust system

Abstract

The invention discloses an intelligent control safety valve steam exhaust system, which relates to the technical field of safety valve steam exhaust systems, and comprises a pressure detection unit, a variable frequency control valve, a safety valve assembly, an intelligent control unit and a communication module. The pressure detection unit monitors steam exhaust pressure and temperature in real time; the variable-frequency regulating valve dynamically regulates the opening degree to control the flow; emergency exhausting is performed when the safety valve assembly overpressure or temperature is abnormal; the intelligent control unit calculates the target steam exhaust amount by means of a PID algorithm, monitors abnormity and triggers a safety valve, and an equipment module is used for preventing faults; and the communication module supports remote data transmission and regulation. The system can accurately adjust flow, reduce energy consumption, guarantee safety through multiple protection, is convenient to operate and maintain, and is suitable for boilers, pressure vessels and other high-temperature and high-pressure scenes, the communication module supports remote data transmission and interaction with a cloud management platform, remote regulation and control and state monitoring of system parameters are achieved, the manual inspection burden is reduced, and the operation and maintenance efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of safety valve exhaust system technology, specifically to an intelligent control safety valve exhaust system. Background Technology

[0002] In industrial production processes, especially in systems involving boilers, pressure vessels, and high-temperature, high-pressure pipelines, safety valves are critical equipment for ensuring safe system operation. Traditional safety valve systems mostly employ mechanical structures, relying on mechanical components such as springs or counterweights to achieve overpressure protection. Their operating thresholds are typically fixed and cannot be dynamically adjusted according to changes in system operating conditions. When the system pressure approaches the set threshold, traditional safety valves often open directly to release gas, resulting in energy waste, media loss, and potentially accelerated valve wear due to frequent opening and closing, affecting system stability.

[0003] Furthermore, traditional safety valve systems lack real-time monitoring and intelligent control capabilities, making it impossible to continuously collect and analyze key parameters such as pressure and temperature, and even more difficult to achieve remote monitoring and data interaction. When pressure fluctuations or abnormal operating conditions occur in the system, they can only rely on mechanical safety valves for passive response, unable to provide early warnings or proactive adjustments, posing certain safety hazards. While some systems incorporate electric or pneumatic regulating valves, these typically operate independently of the safety valves, lacking a coordinated control mechanism, making it difficult to improve system efficiency while ensuring safety. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent control safety valve exhaust system to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an intelligent control safety valve exhaust system, comprising: Pressure detection unit: Located on the main channel of the exhaust pipeline, it includes a pressure transmitter and a temperature sensor for real-time monitoring of exhaust pressure and temperature; Variable frequency control valve: installed downstream of the main channel, it dynamically adjusts the valve opening to regulate the exhaust steam flow by receiving feedback signals from the pressure detection unit; Safety valve assembly: A bypass branch connected in parallel to the main channel, comprising at least one mechanical safety valve and an electric opening and closing device for emergency venting in case of overpressure or abnormal temperature. Intelligent control unit: electrically connected to the pressure detection unit, frequency converter valve and safety valve assembly; built-in PID algorithm module, calculates the target exhaust steam volume based on real-time pressure-temperature data, outputs control signal to frequency converter valve to adjust opening degree; at the same time, monitors abnormal operating conditions through threshold judgment module and triggers the opening and closing of safety valve assembly; Communication module: Integrated into the intelligent control unit, it supports remote data transmission and status monitoring, and interacts with the cloud management platform to realize remote control of system parameters.

[0006] Furthermore, the pressure transmitter in the pressure detection unit is made of diffused silicon material, with a measurement range covering 0-10MPa, and the temperature sensor is an NTC thermistor with an anti-electromagnetic interference coating; both are encapsulated by a waterproof sealed shell.

[0007] Furthermore, the intelligent control unit is equipped with an independent backup control module, which can automatically switch to the backup module when the main module fails, with a switching time of ≤0.1s; at the same time, it has a built-in storage chip that can cache pressure, temperature and valve status data for 72 hours.

[0008] Furthermore, the communication module is equipped with an RS485 wired communication interface, which supports docking with the field PLC control system; a data verification mechanism is adopted during data transmission, and each frame of data contains a CRC check code.

[0009] Furthermore, the bypass branch is equipped with a filter upstream of the safety valve assembly, and the filter screen can filter impurities in the exhaust steam; the filter screen has a detachable structure.

[0010] Furthermore, the intelligent control unit is connected to an external audible and visual alarm. When an overpressure or temperature abnormality is detected, in addition to triggering the safety valve assembly, the audible and visual alarm will simultaneously emit a red flash and an alarm sound of more than 80dB to remind on-site personnel to check the working conditions in a timely manner.

[0011] Furthermore, the variable frequency control valve is equipped with an opening feedback sensor, which transmits the actual valve opening data to the intelligent control unit in real time. The control unit compares the target opening with the actual opening, and if the deviation exceeds 2%, it automatically corrects the control signal to ensure the accuracy of the exhaust flow regulation.

[0012] Compared with the prior art, the beneficial effects of the present invention are: The system collects exhaust steam pressure and temperature data in real time through a pressure detection unit. Combined with the PID algorithm module in the intelligent control unit, it dynamically calculates the target exhaust steam volume and controls the opening of the variable frequency control valve, achieving precise regulation of the exhaust steam flow. This avoids the problem of frequent opening and closing of traditional safety valves due to fixed thresholds, effectively reducing media discharge and energy waste, and improving the system's operational economy.

[0013] The system features a bypass branch connected in parallel to the main channel, where the safety valve assembly is triggered by the intelligent control unit in case of overpressure or abnormal temperature, enabling emergency venting. Simultaneously, the system incorporates multiple redundancy designs, such as a backup control module that automatically switches in case of main module failure to ensure uninterrupted control; and audible and visual alarms that promptly alert on-site personnel in abnormal operating conditions, further enhancing the system's safety protection capabilities.

[0014] The intelligent control unit has a built-in storage chip that can cache operational data for up to 72 hours, facilitating fault tracing and analysis. The communication module supports remote data transmission and interaction with the cloud management platform, enabling remote control of system parameters and status monitoring, reducing the burden of manual inspections and improving operational efficiency.

[0015] The pressure detection unit employs an anti-interference sensor, and the frequency converter valve is equipped with an opening feedback sensor to ensure stable system operation under complex conditions. The filter installed in the bypass branch effectively filters impurities in the exhaust steam, preventing valve blockage and extending equipment lifespan. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the system flow of the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] See Figure 1 This invention provides a technical solution: an intelligent control safety valve exhaust system, comprising: Pressure detection unit: Located on the main channel of the exhaust pipeline, it includes a pressure transmitter and a temperature sensor for real-time monitoring of exhaust pressure and temperature; The pressure detection unit is fixed at a straight pipe section in the main exhaust channel at a distance of ≥3 times the pipe diameter from elbows, valves and other disturbing components to ensure stable detection data; the sensor probe is flush with the inner wall of the pipe to avoid interference from the flow of the medium.

[0019] The pressure transmitter has an accuracy class of ≤0.2%FS and a response time of ≤50ms; the NTC thermistor has a measurement range of -40℃ to 200℃ and an accuracy of ±0.5℃; the anti-electromagnetic interference coating meets the IP67 protection standard; the waterproof sealed housing is made of 304 stainless steel and can withstand pressure ≥1.5 times the rated pressure of the system.

[0020] Calibration is performed every 6 months using a standard pressure and temperature source. Calibration records are automatically stored in the intelligent control unit. Failure to calibrate within the specified period will trigger an audible and visual alarm.

[0021] Variable frequency control valve: installed downstream of the main channel, it dynamically adjusts the valve opening to regulate the exhaust steam flow by receiving feedback signals from the pressure detection unit; The valve body of the variable frequency control valve is made of cast steel, and the sealing surface is made of hard alloy. It is suitable for media with a temperature of ≤400℃ and a pressure of ≤10MPa. The valve stem is equipped with a dustproof sealing ring to prevent impurities from entering and affecting the opening control.

[0022] The valve opening feedback sensor has a resolution of 0.1%. When the deviation between the target opening and the actual opening exceeds 2%, the intelligent control unit corrects the output signal within 500ms. The valve's full stroke time is ≤3s, meeting the requirements for dynamic adjustment.

[0023] The valve body has an inspection port on the side, which allows for the replacement of seals while the system is under pressure; the valve position indicator displays the actual opening degree in real time, which is convenient for on-site inspection and observation.

[0024] Safety valve assembly: A bypass branch connected in parallel to the main channel, comprising at least one mechanical safety valve and an electric opening and closing device for emergency venting in case of overpressure or abnormal temperature. The safety valve assembly includes at least one spring-loaded safety valve with a nominal pressure matching the system rated pressure, and one electric butterfly valve, both connected in parallel and both having manual emergency opening and closing functions.

[0025] The filter screen is made of 316L stainless steel with a pore size ≤0.5mm and a filtration area ≥2 times the cross-sectional area of ​​the pipeline. A differential pressure sensor is installed on the outside of the filter screen; when the differential pressure exceeds 0.1MPa, a "filter clogging" alarm is triggered, reminding the user to replace the filter. The detachable filter screen uses a quick-release clip structure, allowing for replacement in ≤5 minutes without disassembling the pipeline. Intelligent control unit: electrically connected to the pressure detection unit, frequency converter valve and safety valve assembly; built-in PID algorithm module, calculates the target exhaust steam volume based on real-time pressure-temperature data, outputs control signal to frequency converter valve to adjust opening degree; at the same time, monitors abnormal operating conditions through threshold judgment module and triggers the opening and closing of safety valve assembly; Both the main and backup control modules use industrial-grade CPUs with an operating frequency of ≥1GHz and memory of ≥512MB; the storage chip capacity is ≥8GB, which can store 72 hours of real-time data in addition to caching historical fault records and calibration data for 1 year, and supports export via USB interface.

[0026] When the main module fails, the backup module will automatically switch within ≤0.1s. During the switching process, the frequency converter valve will maintain its current opening to avoid flow fluctuations. The switching status will be displayed in real time by indicator lights.

[0027] The built-in threshold determination module supports custom multi-level thresholds, such as "early warning threshold" and "action threshold", with different thresholds corresponding to different response strategies.

[0028] Communication module: Integrated into the intelligent control unit, it supports remote data transmission and status monitoring, and interacts with the cloud management platform to realize remote control of system parameters.

[0029] In addition to the RS485 wired interface, the communication module adds a LoRa wireless communication module and a 4G / 5G module to adapt to wireless scenarios; all interfaces have surge protection.

[0030] Employing a dual-mode transmission of "real-time + timed" data, pressure and temperature data are uploaded every second, and valve status and alarm information are pushed out instantly. Operational reports are generated periodically, including statistical data such as average pressure and valve actuation frequency. In addition to CRC checksums, a new data encryption algorithm is added to prevent tampering during transmission.

[0031] It supports two-way communication with the cloud management platform, allowing remote modification of PID parameters.

[0032] The pressure transmitter in the pressure detection unit is made of diffused silicon and has a measurement range of 0-10MPa. The temperature sensor is an NTC thermistor with an anti-electromagnetic interference coating. Both are encapsulated in a waterproof and sealed housing.

[0033] The intelligent control unit has an independent backup control module. When the main module fails, it can automatically switch to the backup module with a switching time of ≤0.1s. It also has a built-in storage chip that can cache pressure, temperature and valve status data for 72 hours.

[0034] The communication module is equipped with an RS485 wired communication interface, which supports docking with the field PLC control system; a data verification mechanism is used during data transmission, and each frame of data contains a CRC check code.

[0035] A filter is installed upstream of the safety valve assembly in the bypass branch. The filter screen can filter impurities in the exhaust steam; the filter screen has a detachable structure.

[0036] The intelligent control unit is connected to an external audible and visual alarm. When an overpressure or temperature abnormality is detected, in addition to triggering the safety valve assembly, the audible and visual alarm will simultaneously emit a red flash and an alarm sound of more than 80dB to remind on-site personnel to check the working condition in a timely manner.

[0037] The audible and visual alarm should be fixed in a location near the system that is easily noticeable to people, at a height of 1.5~2m, to avoid obstruction; the alarm sound coverage range should be ≥50m, the red flash frequency should be 2Hz, and the flash intensity should be ≥100cd.

[0038] Alarm modes are differentiated based on the type of fault. For example, "overpressure alarm" is triggered continuously by sound and light, while "filter blockage" is triggered intermittently by sound and light, making it easier for staff to quickly identify the level of fault.

[0039] The variable frequency control valve is equipped with an opening feedback sensor, which transmits the actual valve opening data to the intelligent control unit in real time. The control unit compares the target opening with the actual opening. If the deviation exceeds 2%, it automatically corrects the control signal to ensure the accuracy of exhaust flow regulation.

[0040] When the ambient temperature is below -10℃, the intelligent control unit automatically activates the heating module to maintain the internal component temperature between 0℃ and 50℃; low-temperature grease is added to the valve stem of the frequency converter to prevent low-temperature jamming. The pressure detection unit and intelligent control unit are fixed with anti-vibration brackets with a damping coefficient ≥0.3 to reduce the impact of pipeline vibration on the equipment; the communication module antenna adopts an anti-vibration design to avoid signal interruption caused by vibration.

Claims

1. A smart control safety valve exhaust system, characterized in that, include: Pressure detection unit: Located on the main channel of the exhaust pipeline, it includes a pressure transmitter and a temperature sensor for real-time monitoring of exhaust pressure and temperature; Variable frequency control valve: installed downstream of the main channel, it dynamically adjusts the valve opening to regulate the exhaust steam flow by receiving feedback signals from the pressure detection unit; Safety valve assembly: A bypass branch connected in parallel to the main channel, comprising at least one mechanical safety valve and an electric opening and closing device for emergency venting in case of overpressure or abnormal temperature. Intelligent control unit: electrically connected to the pressure detection unit, frequency converter valve and safety valve assembly; built-in PID algorithm module, calculates the target exhaust steam volume based on real-time pressure-temperature data, outputs control signal to frequency converter valve to adjust opening degree; at the same time, monitors abnormal operating conditions through threshold judgment module and triggers the opening and closing of safety valve assembly; Communication module: Integrated into the intelligent control unit, it supports remote data transmission and status monitoring, and interacts with the cloud management platform to realize remote control of system parameters.

2. The intelligent control safety valve exhaust system according to claim 1, characterized in that, The pressure transmitter in the pressure detection unit is made of diffused silicon material, with a measurement range covering 0-10MPa. The temperature sensor is an NTC thermistor with an anti-electromagnetic interference coating. Both are encapsulated in a waterproof and sealed housing.

3. The intelligent control safety valve exhaust system according to claim 1, characterized in that, The intelligent control unit is equipped with an independent backup control module. When the main module fails, it can automatically switch to the backup module with a switching time of ≤0.1s. It also has a built-in storage chip that can cache pressure, temperature and valve status data for 72 hours.

4. The intelligent control safety valve exhaust system according to claim 1, characterized in that, The communication module is equipped with an RS485 wired communication interface, which supports docking with the field PLC control system; a data verification mechanism is used during data transmission, and each frame of data contains a CRC check code.

5. The intelligent control safety valve exhaust system according to claim 1, characterized in that, The bypass branch has a filter installed upstream of the safety valve assembly. The filter screen can filter impurities in the exhaust steam; the filter screen has a detachable structure.

6. The intelligent control safety valve exhaust system according to claim 1, characterized in that, The intelligent control unit is connected to an external audible and visual alarm. When an overpressure or temperature abnormality is detected, in addition to triggering the safety valve assembly, the audible and visual alarm will simultaneously emit a red flash and an alarm sound of more than 80dB to remind on-site personnel to check the working conditions in a timely manner.

7. The intelligent control safety valve exhaust system according to claim 1, characterized in that, The variable frequency control valve is equipped with an opening feedback sensor, which transmits the actual valve opening data to the intelligent control unit in real time. The control unit compares the target opening with the actual opening. If the deviation exceeds 2%, it automatically corrects the control signal to ensure the accuracy of the exhaust flow regulation.

Images