Pressure setting device and method of pilot operated safety valve and hydraulic test system

Abstract

The invention belongs to the field of pressure setting of pilot operated safety valves, and particularly relates to a pressure setting device and method of a pilot operated safety valve and a hydraulic test system. The device comprises a pressing control module, a data processing module and a box body, the pressing control module is used for providing a controllable hydraulic source for the to-be-tested safety valve through the pressure output port; the data processing module is connected with the pressing control module and is used for acquiring a pressure signal of the pressure output port and judging opening and closing fixed values of the safety valve to be tested based on the pressure signal; the box body accommodates and integrates the pressing control module and the data processing module, and provides structural support for connection of an oil path, a gas path and a circuit between the pressing control module and the data processing module. The pressure setting device has the advantages that high-precision control and automatic judgment in the pressure setting process are achieved, transportation and field operation are facilitated due to the integrated box design, and setting efficiency and reliability are effectively improved.

Description

Technical Field

[0001] This invention belongs to the field of pressure setting of pilot-operated safety valves, specifically a pressure setting device, method and hydraulic testing system for a pilot-operated safety valve. Background Technology

[0002] Pilot-operated safety valves are critical safety accessories in nuclear power plants, thermal power plants, and many industrial pressure systems. Their core function is to automatically open and relieve pressure when the system pressure exceeds the allowable value, thereby protecting equipment and personnel. The accuracy of this valve's operation is directly determined by its "set pressure" (i.e., the pressure values ​​for opening and closing). Therefore, regularly performing pressure setting calibration on safety valves is an indispensable maintenance step to ensure their reliability and the safe operation of the system.

[0003] Currently, on-site pressure setting of pilot-operated safety valves typically relies on a decentralized set of calibration equipment. Operators must transport individual pieces of equipment, including manual or electric test pumps, multiple valves, pressure gauges, pressure sensors, and data loggers, to the site and assemble a test system via temporary connecting pipelines and cables. During calibration, the pumps and valves are primarily operated manually to control the rate of pressure increase and decrease. Changes in the readings of pointer-type pressure gauges or sensors are observed visually, and experience is used to determine the valve's opening and closing times. Relevant pressure data is then manually recorded.

[0004] However, existing verification methods rely on loosely combined equipment and manual experience, resulting in low on-site work efficiency and insufficient pressure control precision. Furthermore, the lack of automated data acquisition and processing capabilities makes it difficult to standardize the testing process and achieve traceability and scientific management of test results.

[0005] Pilot-operated safety valves are critical safety protection devices widely used in high-pressure systems in nuclear energy, power, chemical and other fields. They sense system pressure through a pilot valve and control the opening and closing of the main valve. They are characterized by sensitive operation, good sealing, and small pressure differential during opening and closing, and their performance directly affects the safety and reliability of the entire pressure system.

[0006] Pressure setting of a pilot-operated safety valve refers to the process of applying a controllable and slowly varying pressure to the valve to induce it to accurately complete the opening and closing actions at a specific pressure value, thereby measuring and verifying its key performance parameters.

[0007] Currently, on-site verification typically relies on a temporary, assembled testing system. This system consists of a separate pneumatic or electric pressure pump, multiple shut-off and regulating valves, mechanical pressure gauges or distributed digital pressure sensors, and a separate data logger or manual recorder. Operators must move this equipment on-site and manually connect the oil, pneumatic, and electrical lines. During verification, the operator relies entirely on manually adjusting the valve openings to control the rate of pressure rise and fall, visually observing the changes in pressure gauge or sensor readings, judging the valve opening and closing times based on personal experience, and then manually recording the data. Summary of the Invention

[0008] The purpose of this invention is to provide a pressure setting device, method, and hydraulic testing system for a pilot-operated safety valve. By integrating high-precision controllable pressure testing, real-time data acquisition and intelligent analysis, and an integrated portable housing, the pressure setting process of the pilot-operated safety valve is fully automated, highly accurate, and efficient in the field.

[0009] The technical solution of the present invention is as follows: a pressure setting device for a pilot-operated safety valve, comprising: a pressure control module, a data processing module, and a housing; The pressure control module is used to provide a controllable hydraulic source to the safety valve under test through the pressure output port; The data processing module is connected to the pressure control module. The data processing module is used to collect the pressure signal from the pressure output port and determine the opening and closing setpoints of the safety valve under test based on the pressure signal. The enclosure houses and integrates the pressure control module and the data processing module, and provides structural support for the oil circuit, air circuit and electrical connection between the pressure control module and the data processing module.

[0010] The enclosure includes an upper cover, an upper operating table, and a lower storage area; The top cover is detachably mounted on the top of the housing; The upper control panel is located on the upper part of the housing and is used to support the terminal equipment of the data processing module and the operating components of the pressure control module; The lower storage area is located at the bottom of the enclosure and is used to house the pneumatic-driven liquid pump, accumulator, and battery that powers the device of the pressure control module.

[0011] The enclosure includes a front panel with a main panel and a footstool, and a side panel with slots. The footstool is folded and mounted on the main panel, and the front panel is installed on the front of the housing; or... The main panel is mounted on the side panel by engaging with the slot, and the footstool unfolds to form an angle with the main panel to support the main panel.

[0012] The enclosure also includes a storage drawer; the storage drawer is located below the upper control panel and is used to store auxiliary components.

[0013] The pressurization control module includes a pneumatic hydraulic pump, an accumulator, and a regulating valve group with a slow pressurization branch and a slow depressurization branch connected in parallel. The gas-driven liquid pump is used to convert external gas power into hydraulic pressure. The accumulator is connected to the output end of the gas-driven liquid pump via an oil circuit, and is used to store the pressure energy of the liquid pressure. The slow-speed boosting branch connects the accumulator to the pressure output port, and the slow-speed depressurization branch connects the pressure output port to a depressurization port; the regulating valve group is used to regulate the pressure output to the pressure output port based on the pressure energy by controlling the on / off state and opening degree of the slow-speed boosting branch and the slow-speed depressurization branch.

[0014] The slow boosting branch includes a slow boosting switching valve and a slow boosting regulating valve connected in series. The slow boosting switching valve and the slow boosting regulating valve are used to jointly control the on / off state and flow rate of the slow boosting branch. The slow pressure relief branch includes a slow pressure relief switch valve and a slow pressure relief regulating valve connected in series; the slow pressure relief switch valve and the slow pressure relief regulating valve are used to jointly control the on / off state and flow rate of the slow pressure relief branch.

[0015] The pressurization control module includes an inflation branch equipped with a check valve; The inflation branch connects an external air source to the pressure output port; The inflation branch is used to provide auxiliary air source pressure to the pressure output port, and the check valve is used to prevent the medium at the pressure output port from flowing back to the external air source.

[0016] The data processing module includes a pressure transmitter, a data acquisition unit, and a terminal device. The pressure transmitter is connected to the pressure transmitter inlet of the pressure control module. The data acquisition unit is electrically connected to the pressure transmitter and is used to receive pressure signals; The terminal device is communicatively connected to the data acquisition unit, and is used to process the pressure signal, display the pressure curve, and identify the opening and closing points of the safety valve.

[0017] A pressure setting method for a pilot-operated safety valve, the method being applied to a pressure setting device, includes the following steps: The accumulator of the pressure control module is charged with a pressure higher than the expected opening value of the safety valve; The pressure control module is controlled to increase the pressure through the slow pressurization branch at a first preset rate until the safety valve opens, and the data processing module monitors and judges to determine the opening set value of the safety valve. The pressure control module is controlled to reduce the pressure through the slow pressure relief branch at a second preset rate until the safety valve closes. The data processing module monitors and judges the pressure to determine the closing set value of the safety valve.

[0018] A hydraulic testing system includes a pressure setting device, a water tank, and a compressed air supply device; The water tank is used to provide a water source for the pressure setting device; The compressed air supply device is used to provide an air source for the pressure setting device.

[0019] The beneficial effects of this invention are as follows: The pressure setting device provided by this invention significantly improves the efficiency, control accuracy, and reliability of on-site pressure setting work, and realizes the standardization of the testing process and the automated management of data. The pressure setting device for the pilot-operated safety valve provided by this invention includes an upper cover plate, an upper operating platform, and a lower storage area, realizing functional zoning and compact layout. The upper cover plate serves both protective and auxiliary office functions, the upper operating platform centralizes all human-machine interaction and monitoring equipment, conforming to operational logic; the lower storage area stably supports heavy power components, ensuring structural stability and portability. This makes the entire device compact in structure and clearly functional in zoning, greatly facilitating on-site transportation, rapid deployment, and efficient operation. The front panel of the pressure setting device for the pilot-operated safety valve provided by this invention serves as a protective component for the housing in the folded state; in the unfolded state, it transforms into a practical on-site workbench. This greatly enhances the on-site adaptability and ease of operation of the device, eliminating the need to carry an additional independent workbench, saving space and preparation time, and is particularly suitable for use in industrial sites with limited space or complex environments. The pressure setting device for the pilot-operated safety valve provided by this invention features a dedicated storage drawer inside its housing, providing a centralized and protected storage space for various small auxiliary components necessary for calibration. This avoids the risk of components being scattered or lost, making preparations before and after on-site operations more efficient and orderly. The pressure control module in this invention overcomes the instability of direct-drive pump fine-tuning by incorporating an accumulator and regulating valve, achieving reliable control of the output pressure change rate and fundamentally ensuring the process accuracy and result accuracy required for safety valve setting tests. The switching valve ensures reliable start and stop of the process, while the regulating valve provides stepless, continuous, and precise rate adjustment; effectively ensuring the linearity and stability of pressure changes during setting, overcoming the difficulty of precisely controlling the rate through manual operation, thereby significantly improving the accuracy of safety valve opening and closing setpoint detection and overall testing efficiency. This invention introduces an independent, controllable, and safe air source interface for the pressure setting value by adding an air charging branch with a check valve to the pressure control module. This invention ensures accurate signal source through a high-precision pressure transmitter, achieves high-fidelity digitization of the signal via a professional data acquisition device, and finally completes data visualization and automated analysis in the intelligent software of the terminal device. It transforms the traditional calibration process, which relies on manual observation and recording, into an objective, precise, and traceable automated process, significantly improving the efficiency, accuracy, and standardization of calibration work. The pilot-operated safety valve calibration method provided by this invention, through a standardized high-pressure pre-charge-slow pressure increase judgment-slow pressure release judgment process, transforms the traditional value determination method, which relies on human sensory judgment, into an objective, quantitative, and automatically executable precision testing process, significantly improving the accuracy, efficiency, and traceability of the calibration results. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the pressure setting device for a pilot-operated safety valve provided in an embodiment of the present invention. Figure 2 A schematic diagram of the housing provided in an embodiment of the present invention; Figure 3 This is an example diagram illustrating the usage scenario of the enclosure provided in this embodiment of the invention; Figure 4 This is an example diagram showing the arrangement of the functional components of the control panel provided in an embodiment of the present invention; Figure 5 This is a schematic diagram showing the connection between the upper operation panel and the internal components of the housing, provided in an embodiment of the present invention. Figure 6 A schematic diagram of the pressure control module provided in an embodiment of the present invention; Figure 7 This is a schematic diagram showing the connection between the overall pressure testing tool and the pilot-operated safety valve provided in an embodiment of the present invention; Figure 8 This is a connection diagram of the data processing module provided in an embodiment of the present invention; Figure 9 This is a schematic diagram of the pressure setting system interface provided in an embodiment of the present invention; Figure 10 This is the interface of the pressure holding test system provided in the embodiments of the present invention; Figure 11 This is a schematic diagram of a device database provided in an embodiment of the present invention; Figure 12 This is a schematic diagram of the device parameter setting interface provided in an embodiment of the present invention; Figure 13 Historical data example diagram provided for embodiments of the present invention; Figure 14 Historical curve example diagram provided for embodiments of the present invention; Figure 15 Example diagram of a repair report provided in an embodiment of the present invention; Figure 16 This is a flowchart illustrating the steps of the pilot-operated safety valve setting method provided in an embodiment of the present invention. Figure 17 A schematic diagram of a hydraulic testing system provided in an embodiment of the present invention; Figure 18 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present invention.

[0021] In the diagram: 100 Pressure setting device; 110 Pressure control module; 111 Gas-driven liquid pump; 112 Accumulator; 113 Regulating valve group; C1 Slow pressure boosting branch; C2 Slow pressure relief branch; C3 Air charging branch; C31 Check valve; 120 Data processing module; 121 Pressure transmitter; 122 Data acquisition unit; 123 Terminal equipment; 130 Housing; 131 Top cover; 132 Upper operating platform; 133 Lower storage area; S1 Front panel; S2 Side panel; L slot; a Panel body; b Footstool; P Pressure output port; 200 Electronic equipment; 201 Processor; 202 Memory. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0023] Therefore, the following detailed description of embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed embodiments, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the embodiments of the invention.

[0024] Loosely combined equipment leads to low field deployment efficiency and poor portability; manual control of pressure curves makes it difficult to ensure the linearity and stability of pressure increase and decrease rates, resulting in fluctuating setting accuracy and poor reproducibility; at the same time, the collection, processing and archiving of test data depend on manual labor, the process is difficult to standardize, the data is prone to errors and is not conducive to long-term traceability and scientific analysis.

[0025] Based on this, the present invention proposes a pressure setting device 100 for a pilot-operated safety valve. This device effectively solves problems such as poor portability, low pressure control accuracy, and cumbersome manual data processing by integrating a pressure control module providing a controllable hydraulic source, a data processing module responsible for signal acquisition and automatic judgment, and all functional units into a compact, integrated structure within a housing. Its technical advantages lie in achieving a high degree of integration and portability of the setting device, improving the accuracy and automation level of pressure control, and ensuring the standardization and traceability of the testing process and result data.

[0026] Based on this, the present invention proposes a pressure setting device, method, and hydraulic testing system for a pilot-operated safety valve. This pressure setting device for the pilot-operated safety valve integrates high-precision controllable pressure testing, real-time data acquisition and intelligent analysis, and a portable integrated housing, achieving fully automated, high-precision, and efficient on-site operation of the pressure setting process.

[0027] like Figure 1 As shown, the present invention provides a pressure setting device 100 for a pilot-operated safety valve, which includes a pressure control module 110, a data processing module 120, and a housing 130.

[0028] The pressure control module 110 is used to provide a controllable hydraulic source to the safety valve under test through the pressure output port P.

[0029] The pressure control module 110 is used to generate and adjust the hydraulic pressure required for testing. In this embodiment, the pressure control module 110 includes a pressure output port P, which is connected to the inlet of the safety valve under test via a high-pressure hose. Internally, it integrates a power unit and a pressure regulating unit, capable of converting externally supplied water and compressed air into a stable and controllable hydraulic fluid. By operating the control components on this module, the liquid pressure output from the pressure output port P can be precisely controlled, achieving a slow, linear rise and fall, thereby providing a controllable hydraulic source that meets standard requirements for the safety valve's calibration test.

[0030] The data processing module 120 is connected to the pressure control module 110. The data processing module 120 is used to collect the pressure signal from the pressure output port P and determine the opening and closing setpoints of the safety valve under test based on the pressure signal.

[0031] The data processing module 120 is responsible for signal acquisition, processing, and judgment. For example, this module acquires the pressure signal from the pressure output port P in real time using a high-precision pressure sensor and converts this analog signal into digital data. The converted data is transmitted to the host computer, where a specific analysis algorithm is used to monitor and identify the continuous pressure-time curve in real time. This allows for the automatic and accurate determination of the pressure setpoints corresponding to the opening and closing of the safety valve, and the output of the final test results.

[0032] The housing 130 houses and integrates the pressure control module 110 and the data processing module 120, and provides structural support for the oil circuit, air circuit and electrical circuit connection between the pressure control module 110 and the data processing module 120.

[0033] The internal space of the enclosure 130 is planned to accommodate and secure the functional units of the pressure control module 110 and the data processing module 120. It is important to note that the enclosure 130 pre-lays and integrates the necessary oil lines, compressed air lines, and electrical cables for connecting the pressure control module 110 and the data processing module 120. This ensures stable and coordinated operation between the modules, giving the device excellent overall integrity and portability.

[0034] pass Figure 1 As can be seen, the pressure calibration device 100 provided in this embodiment of the invention, through the pressure control module 110, the data processing module 120, and the integration of all components into a single housing 130, successfully integrates the traditionally decentralized, manual calibration process into a portable device. The pressure calibration device 100 provided in this embodiment of the invention significantly improves the efficiency, control accuracy, and reliability of on-site pressure calibration work, and achieves standardization of the testing process and automated data management.

[0035] like Figure 2 and 3 As shown, in this embodiment of the invention, the housing 130 includes an upper cover plate 131, an upper operating table 132, and a lower storage area 133.

[0036] The top cover 131 is foldably mounted on the top of the housing 130.

[0037] Optionally, the upper cover 131 is connected to the main body of the housing 130 via a hinge and a hydraulic support rod. In the closed state, as... Figure 2 As shown, it is flush with the top surface of the housing 130, together forming the complete outer casing outline, serving a protective function. When operation is required, such as... Figure 3 As shown, it can be manually lifted, and the hydraulic support rod will automatically and smoothly open the upper cover 131 and stabilize it in a near-vertical position. The surface of the upper cover 131 is preferably equipped with a document holder for securing drawings, data records, and other documents during testing. Documents are easy to remove and place, facilitating document retrieval during verification. After testing, the upper cover 131 is pressed down, and it returns to its original position. Figure 2 The horizontal position shown.

[0038] The upper control panel 132 is located on the upper part of the housing 130 and is used to support the terminal device 123 of the data processing module 120 and the operating components of the pressure control module 110.

[0039] Please refer to Figure 3The upper control panel 132 is located in the upper part of the enclosure 130 and is fully exposed after the upper cover 131 is opened. This control panel is a structured support platform with standardized mounting positions and cable trays on its surface or panel. Specifically, the regulating valve group operating handle, status indicator lights, and instruments of the pressure control module 110 are centrally arranged on the control panel; at the same time, the terminal device 123 of the data processing module 120, the data acquisition host, and the micro printer are also integrated and installed in this area, and the power supply and signal cables of all devices are neatly laid out through preset channels.

[0040] Furthermore, in this embodiment of the invention, a sealed cavity is provided below the control panel to accommodate the core valve group of the pressure control module 110, and multiple wiring holes and through holes are reserved at the bottom of the control panel for connecting high-pressure oil pipes, air pipes, and power supply cables to the lower part of the housing 130, respectively. Please refer to [reference needed]. Figure 5 , Figure 5 This is a schematic diagram showing the connection between the upper operation panel and the internal components of the housing 130, as provided in an embodiment of the present invention.

[0041] like Figure 4 As shown, in a specific embodiment of the present invention, the upper operating panel 132 is a highly integrated functional panel area. The operating panel of the pressure control module 110 is fixed to the top layer of this area, and its operating handles, pressure gauges, and switches for regulating valves such as slow pressurization and slow depressurization are clearly arranged on it. Below the operating panel is a sealed cavity, in which the core valve group and pipelines of the pressure control module 110 are fixedly installed by screws. The operating panel surface is also planned with dedicated mounting slots for embedding and fixing the setter acquisition host of the data processing module 120 and the micro printer. Each slot can be equipped with a customized plastic liner or a snap-fit ​​shaping block to ensure the stability of the host and printer during transportation and use.

[0042] The lower storage area 133 is located at the lower part of the housing 130 and is used to house the pneumatic pump 111 of the pressure control module 110, the accumulator 112, and the battery that powers the device.

[0043] Please continue reading. Figure 3The lower storage area 133 constitutes the main space of the lower half of the enclosure 130, where the core power and energy storage components are securely fixed by mounting brackets and shock-absorbing pads. Specifically, this includes: the pneumatic-driven hydraulic pump 111, accumulator 112, and oil mist filter of the pressure control module 110, all secured by base bolts; and a large-capacity battery pack providing independent power to the entire device. The pneumatic-driven hydraulic pump 111 and accumulator 112 are connected to the valve group of the pressure control module 110 on the upper control panel via high-pressure oil and air pipes and through wiring holes. The battery supplies power to the data acquisition unit 122 host located on the upper control panel 132 via wires. This host unit has an expansion power interface to power the terminal device 123 and printer. In addition, the lower storage area 133 also includes an open storage space for storing spare high-pressure hoses, quick connectors, and commonly used consumables.

[0044] Optionally, the rear of the enclosure 130 is typically equipped with an openable access door to facilitate routine inspection and maintenance of the internal pumps, valves and batteries.

[0045] Optionally, the lower storage area 133 is designed with a reinforced frame to ensure it can withstand the vibration and weight of the device during operation.

[0046] Optionally, the bottom of the housing 130 is equipped with casters and the sides are fitted with handles to facilitate the movement and transportation of the entire device.

[0047] Optionally, the 130 case uses aluminum alloy edging, which is sturdy, lightweight, and has a height of about 0.5m-1m.

[0048] pass Figures 2 to 4 As can be seen, the pressure setting device 100 for the pilot-operated safety valve provided in this embodiment of the invention includes an upper cover plate 131, an upper operating platform 132, and a lower storage area 133, achieving functional zoning and a compact layout. The upper cover plate 131 serves both protective and auxiliary office functions, while the upper operating platform 132 centralizes all human-machine interaction and monitoring equipment, conforming to operational logic. The lower storage area 133 stably supports heavy-duty power components, ensuring structural stability and portability. This makes the entire device compact in structure and clearly functionally divided, greatly facilitating on-site transportation, rapid deployment, and efficient operation.

[0049] Please continue reading. Figure 2 and Figure 3 In this embodiment of the invention, the housing 130 includes a front panel S1 having a panel body a and a footstool b, and a side panel S2 having a slot L.

[0050] In the folded state, footstool b is folded onto panel body a, and front panel S1 is mounted on the front of housing 130.

[0051] In the normal storage or transportation state of the front panel S1, i.e., the folded state, the footstool b is completely folded and fits against the inner surface or side edge of the main panel a. For example... Figure 2 As shown, at this time, the front panel S1 is securely installed on the front of the enclosure 130 by means of a buckle, lock or quick connector, and is used as a door to protect and seal the interior of the enclosure 130.

[0052] In the unfolded state, the main panel a is installed on the side panel S2 by engaging with the slot L, and the footstool b unfolds to form an angle with the main panel a to support the main panel a.

[0053] like Figure 3 As shown, when a work surface is needed on site, the front panel S1 can be removed from the front of the housing 130. Then, align the panel body a with and insert it into the pre-set slot L on the side of the housing 130, fixing the front panel S1 horizontally or nearly horizontally to the side of the housing 130. Then, unfold the folded footstool b, so that the footstool b forms a stable angle with the panel body a, usually a right angle, with the bottom of the footstool b supporting the ground. Thus, the panel body a, the unfolded footstool b, and the side of the housing 130 together constitute a stable and flat temporary work surface, which can be used to place laptops, record documents, or small tools.

[0054] Therefore, the front panel S1 of the pressure setting device 100 for the pilot-operated safety valve provided in this embodiment of the invention serves as a protective component for the housing 130 in the folded state; and transforms into a practical field workbench in the unfolded state. This greatly enhances the field adaptability and ease of operation of the device, eliminating the need to carry an additional independent workbench, saving space and preparation time, and making it particularly suitable for use in industrial sites with limited space or complex environments.

[0055] Please continue reading. Figure 3 In an optional embodiment of the present invention, the housing 130 further includes a storage drawer; the storage drawer is disposed below the upper operating table 132 and is used to store auxiliary components.

[0056] like Figure 3 As shown, the cabinet 130 also integrates a storage drawer, which is installed in the body of the cabinet 130 via a slide rail mechanism, and its position is limited to directly below the upper worktable 132. The front panel of the drawer is flush with the front panel S1 of the cabinet 130 and is equipped with a handle.

[0057] When needed, with the front panel S1 removed, the operator can smoothly pull the drawer out along the slide rails using the handle. The drawer is used to store auxiliary components such as a computer, pressure transmitter 121, various data cables and wires, etc. After use, the drawer can be pushed back into its original position, and its front panel will revert to being part of the cabinet 130 wall panel, maintaining the overall aesthetic integrity.

[0058] Therefore, it can be seen that the pressure setting device 100 of the pilot-operated safety valve provided in this embodiment of the invention has a dedicated storage drawer inside the housing 130, which provides a centralized and protected storage space for various small auxiliary components necessary for calibration work; it avoids the risk of components being scattered or lost, and makes the preparation work before the on-site operation and the sorting work after the operation more efficient and orderly.

[0059] like Figure 6 As shown, the control module of the pilot-operated safety valve setting device provided in this embodiment of the invention includes a pneumatic pump 111, an accumulator 112, and a regulating valve group 113 having a slow-speed boosting branch C1 and a slow-speed depressurization branch C2 connected in parallel.

[0060] The pneumatic-driven hydraulic pump 111 is used to convert external pneumatic power into hydraulic pressure. For example... Figure 6 As shown, the pump inlet is connected to water from the water tank. Compressed air enters the pressurization unit from the compressed air inlet, passes through a filter and oil mist separator, a compressed air switching valve, and a compressed air regulating valve before entering the pump drive gas inlet. The compressed air switching valve is used to control the on / off of the compressed air, and the compressed air regulating valve is used to regulate the air supply pressure of the downstream pump, thereby regulating the pump's output liquid pressure. The pump is driven by the control system, which pumps water from the water tank into the pressurized side. The water tank can be equipped with a filter to ensure that the water entering the pump is clean.

[0061] Optionally, the pneumatic-driven liquid pump 111 is equipped with a burst valve to prevent system overpressure due to malfunction. When the system is overpressured, the burst valve ruptures.

[0062] Optionally, a pressure gauge is installed after the gas-driven liquid pump 111 to observe the output liquid pressure of the pump.

[0063] Optionally, the main pipe connecting the pneumatic pump 111 to the pressure output port P is equipped with an output switch valve and a high-pressure filter, the filter ensuring that the water entering the equipment is clean.

[0064] Accumulator 112 is connected to the output of pneumatic-driven hydraulic pump 111 via an oil circuit to store the pressure energy of the hydraulic pressure. Please continue reading. Figure 6 The accumulator 112 serves as a storage unit for pressure energy and the working medium, namely water. Its inlet is connected to the output of the pneumatic-driven liquid pump 111 via an oil circuit. The hydraulic pressure generated by the pneumatic-driven liquid pump 111 drives the water medium into the accumulator 112, compressing the nitrogen capsule or piston inside, thereby storing the pressure energy in the form of potential energy.

[0065] A regulating valve group 113 is connected in parallel to the outlet end of the accumulator 112. The regulating valve group 113 is the key to achieving linear and precise pressure control.

[0066] One end of the slow-pressure boosting branch C1 is connected to the outlet of the accumulator 112, and the other end is connected to the pressure output port P. When this branch is open, the pressure energy stored in the accumulator 112 drives the water medium to flow through the regulating valve. By finely adjusting the valve opening, the water medium can be controlled to flow into the pipeline system connected to the safety valve under test at an extremely low flow rate, thereby achieving a slow and linear increase in pressure.

[0067] The slow pressure relief branch C2 is connected to the pressure output port P at one end and to a return pressure relief port at the other end, usually connected to the water tank through a transparent return water pipe. When this branch is open, the pressure in the tested pipeline system drives the water medium to flow out slowly through this branch. The pressure relief rate can be precisely controlled by adjusting the valve opening, achieving a slow and linear decrease in pressure.

[0068] During operation, the accumulator 112 is first charged and stored with sufficient pressure energy exceeding the valve's set value via the pneumatic-driven hydraulic pump 111. Subsequently, relying on the regulating valve assembly 113, the opening and closing of the slow-speed pressurization branch C1 or the slow-speed depressurization branch C2 are precisely controlled. Using the stable pressure energy stored in the accumulator 112 as the source, the pressure output to the safety valve under test is adjusted with high precision and low rate, meeting the stringent requirements of the set test for the rate of pressure change.

[0069] Optionally, a safety valve is provided at the liquid end of the accumulator 112 to ensure that the accumulator 112 will not be used under overpressure and to avoid the safety risk of overpressure of the accumulator 112.

[0070] pass Figure 6 As can be seen, the pressure control module 110 in this embodiment of the invention overcomes the instability when the pump is directly driven for fine-tuning. By setting up an accumulator 112 and a regulating valve, it achieves reliable control over the rate of change of output pressure, fundamentally ensuring the process accuracy and result accuracy required for the safety valve setting test.

[0071] Please continue reading. Figure 6 In an optional embodiment of the present invention, the slow boosting branch C1 includes a slow boosting switch valve and a slow boosting regulating valve connected in series. The slow boosting switch valve and the slow boosting regulating valve are used to jointly control the on / off state and flow rate of the slow boosting branch C1.

[0072] The slow pressure relief branch C2 includes a slow pressure relief switch valve and a slow pressure relief regulating valve connected in series; the slow pressure relief switch valve and the slow pressure relief regulating valve are used to jointly control the on / off state and flow rate of the slow pressure relief branch C2.

[0073] like Figure 6As shown, the slow-pressure boosting branch C1 specifically includes a slow-pressure boosting on / off valve and a slow-pressure boosting regulating valve connected in series. The slow-pressure boosting on / off valve controls the opening and closing of this branch, while the slow-pressure boosting regulating valve finely regulates the flow rate of the medium flowing through the branch after it is opened. The two valves work together to control the on / off state and flow rate of the branch. Similarly, the slow-pressure relief branch C2 specifically includes a slow-pressure relief on / off valve and a slow-pressure relief regulating valve connected in series. By opening and closing the slow-pressure relief on / off valve and adjusting the opening degree of the slow-pressure relief regulating valve, the discharge flow rate from the pressure output port P to the relief port is jointly controlled.

[0074] In actual operation, when slow pressure increase is required, the operator opens the slow pressure increase switch valve and then adjusts the slow pressure increase regulating valve so that the pressure pre-stored in the accumulator 112 can be slowly and smoothly applied to the safety valve under test through this branch. Conversely, when slow pressure decrease is required, the operator opens the slow pressure relief switch valve and adjusts the slow pressure relief regulating valve so that the system pressure can be released slowly and in a controlled manner.

[0075] Therefore, the switching valve ensures the reliable start and stop of the process, while the regulating valve provides stepless and continuous fine adjustment of the rate; it effectively ensures the linearity and stability of pressure changes during the setting process, overcomes the problem of difficulty in accurately controlling the rate by manual operation, and thus significantly improves the accuracy of safety valve opening and closing setpoint detection and overall testing efficiency.

[0076] Please continue reading. Figure 6 In this embodiment of the invention, the pressure control module 110 includes an inflation branch C3 equipped with a check valve C31.

[0077] The inflation branch C3 connects to the external air source and the pressure output port P.

[0078] The inflation branch C3 is used to provide auxiliary air pressure to the pressure output port P, and the check valve C31 is used to prevent the medium at the pressure output port P from flowing back to the external air source.

[0079] Therefore, it can be seen that this embodiment introduces an independent, controllable and safe air source interface for the pressure setting value by adding an air supply branch C3 with a check valve C31 to the pressure control module 110.

[0080] Figure 7 and Figure 8 In the diagram, T1 represents pressure transmitter 1, and T2 represents pressure transmitter 2, used to measure pressure values ​​at different locations. T1 is installed on a pressure testing platform, which simulates the system pressure as the pilot valve output pressure during pressure setting. T1 is used to monitor the real-time output pressure of the pressure testing platform. T2 is installed on the main valve head to monitor the pressure at the main valve head.

[0081] When the pressure on the pressure testing platform is less than the closing setpoint of the safety valve, pilot valve 1 opens and valve 2 closes. The pressure on the pressure testing platform is connected to the main valve head through valve 1, and at this time, the pressure values ​​T1 and T2 are the same. When the pressure on the pressure testing platform is greater than the opening setpoint of the safety valve, valve 1 closes and valve 2 opens. The pressure on the pressure testing platform cannot be connected to the main valve head, and the main valve head is connected to the atmosphere through valve 2. The pressure will be at atmospheric pressure, and the main valve will open. At this time, T1 is the pressure on the pressure testing platform, T2 is atmospheric pressure, and the valve opening pressure is the pressure value of T1 corresponding to the instant when the pressure of T2 drops. The pressure value of T1 at this time is the valve opening setpoint. By slowly lowering the pressure on the pressure testing platform, when the pressure on the pressure testing platform reaches the closing pressure of the safety valve, valve 2 closes and valve 1 opens. The pressure on the pressure testing platform is connected to the main valve head, and the pressures T1 and T2 are the same. The valve closing pressure is the pressure value of T1 corresponding to the instant when the pressure of T1 suddenly drops at the instant when pilot valve 1 opens. The pressure value of T1 at this time is the valve closing setpoint.

[0082] In an optional embodiment of the present invention, the data processing module 120 includes a pressure transmitter 121, a data acquisition unit 122, and a terminal device 123.

[0083] like Figure 7 As shown, pressure transmitter 121 is connected to the pressure transmitter 121 (T1) inlet of pressure control module 110. Data acquisition unit 122 is electrically connected to pressure transmitter 121 and is used to receive pressure signals. Terminal device 123 is communicatively connected to data acquisition unit 122 and is used to process pressure signals, display pressure curves, and identify the opening and closing points of safety valves.

[0084] In the pilot valve setting instrument, the pressure transmitter 121 transmits electrical signals to the data acquisition unit 122 via a cable. The data acquisition unit 122 processes the data and transmits the pressure setpoint information to the computer, i.e., the aforementioned terminal device 123. The pressure value is displayed in the pilot valve setting software specially written in the computer.

[0085] like Figure 8 As shown, a high-capacity battery powers the data acquisition unit 122, the computer, and the micro printer, which prints the report for each test on-site.

[0086] like Figure 9As shown, the setting interface displays real-time pressure values ​​for T1 and T2, and provides a real-time display of pressure curves. The horizontal axis represents time, and the vertical axis represents pressure; the range of both axes can be manually modified. It displays the tag number of the valve being tested, and provides the upper and lower limits for valve opening and closing. It features automatic calculation and indication of the T1 rise and fall rate; when the T1 rise and fall rate is within the acceptable range, the cursor is green; when it is outside the acceptable range, the cursor is red. The software can automatically determine the opening and closing values ​​based on the curve, and the curve can also be manually manipulated, with automatic judgment of the setting results. Test curves and data are automatically saved.

[0087] like Figure 10 As shown, the pressure holding interface displays real-time pressures for T1 and T2, and provides a real-time display of pressure curves. The horizontal axis represents time, and the vertical axis represents pressure; the range of both axes can be manually modified. The pressure holding time can be manually set. It automatically provides the real-time pressure drop for T1 and T2, as well as the total average pressure drop. It can display the tag number of the valve equipment being tested, and the pressure holding curves and data can be automatically saved.

[0088] like Figure 11 As shown, the equipment has a database function, which allows technicians to improve valve and sensor data in advance.

[0089] like Figure 12 and Figure 13 As shown, after completing the equipment information in the database, selecting the equipment code in the parameter settings will automatically display all valve parameter information. The equipment has a historical query function, allowing comparison with similar equipment or historical trends of the same equipment. For example... Figure 14 As shown, the maintenance report query interface allows users to view historical pressure setting data and historical pressure holding test curves.

[0090] Test records matching specific criteria can be queried based on test time, equipment tag number, overhaul number, factory code, and unit information. A list of historical test data can be exported, and useless historical data can be deleted. A specific maintenance report for the equipment can also be exported. Figure 15 As shown, the maintenance report includes all equipment information and test data from this calibration. Equipment information includes: equipment code, test date, factory code, overhaul number, height difference, boss step, T1 and T2 sensor codes, valve opening and closing setpoints and upper and lower limits, actual opening and closing values ​​of the safety valve, and pressure setpoints (units not limited to bar, MPa, etc.). It also provides a conclusion on whether the test was successful, along with the signature of the person in charge and the verification signature.

[0091] Therefore, this embodiment of the invention ensures the accuracy of the signal source through a high-precision pressure transmitter 121, achieves high-fidelity digitization of the signal through a professional data acquisition device 122, and finally completes the visualization and automated analysis of the data in the intelligent software of the terminal device 123. This transforms the traditional calibration process, which relies on manual observation and recording, into an objective, precise, and traceable automated process, significantly improving the efficiency, accuracy, and standardization of calibration work.

[0092] like Figure 16 As shown, the present invention provides a pressure setting method for a pilot-operated safety valve, which is applied to the pressure setting device 100 described above. The method includes the following steps: Step S100: Charge the accumulator 112 of the pressure control module 110 with a pressure higher than the expected opening value of the safety valve.

[0093] In step S100 above, the accumulator 112 of the pressure control module 110 is charged with a pressure higher than the expected opening value of the safety valve, so as to establish a stable high-pressure energy reserve for subsequent precision testing.

[0094] During operation, first reliably connect the pressure output port P of the device to the safety valve under test, and ensure that the slow pressurization and depressurization branches are closed to isolate the test circuit. Then, turn on the pressurization branch of accumulator 112, start the gas-driven liquid pump 111, pressurize the water from the external water source and pump it into accumulator 112 until the pressure gauge of accumulator 112 shows that its pressure value is stable at a preset margin higher than the expected opening value of the safety valve, such as 10%-20%; then stop the pump and close the pressurization branch to complete the high-pressure pre-charge.

[0095] Step S200: Control the pressure control module 110 to make the pressure rise through the slow pressure boosting branch C1 at a first preset rate until the safety valve opens, and monitor and judge through the data processing module 120 to determine the opening set value of the safety valve.

[0096] In step S200 above, the pressure is increased at a controllable low rate and the opening time of the safety valve is accurately determined.

[0097] During operation, the switch valve of the slow-speed boosting branch C1 is opened, and the pressure in the accumulator 112 is slowly released through the branch by finely adjusting the regulating valve on the branch, pushing the system pressure to rise steadily at a first preset rate (e.g., not greater than 0.1 MPa / s). At the same time, the pressure transmitter 121 of the data processing module 120 continuously collects pressure data, and the dedicated software on the terminal device 123 plots the pressure-time curve in real time. The algorithm intelligently identifies characteristic inflection points (such as slight drops or plateaus) on the pressure curve, automatically determines and records the pressure value corresponding to the inflection point as the opening set value of the safety valve.

[0098] Step S300: Control the pressure control module 110 to reduce the pressure through the slow pressure relief branch C2 at a second preset rate until the safety valve is closed, and monitor and judge through the data processing module 120 to determine the closing set value of the safety valve.

[0099] In step S300 above, pressure is released at a controllable low rate and the closing time of the safety valve is accurately determined.

[0100] After the safety valve opens, the slow-speed boosting branch C1 is closed, and the switch valve of the slow-speed depressurization branch C2 is opened instead. By finely adjusting the regulating valve on this branch, the fluid in the system is slowly discharged, causing the system pressure to drop steadily at the second preset rate. During this process, the data processing module 120 continues to monitor the pressure curve and intelligently identifies the second characteristic change point caused by the valve reseating in the pressure drop trend through an algorithm. The pressure value corresponding to this point is automatically determined and recorded as the closing set value of the safety valve.

[0101] pass Figure 16 As can be seen, the pilot-operated safety valve setting method provided by the present invention transforms the traditional value determination method that relies on human sensory judgment into an objective, quantitative, and automatically executable precision testing process through standardized high-pressure pre-charge, slow pressure increase judgment, and slow pressure release judgment. This significantly improves the accuracy, efficiency, and traceability of the setting work.

[0102] like Figure 17 As shown, the present invention provides a hydraulic testing system, which includes the pressure setting device 100, a water tank, and a compressed air supply device.

[0103] The water tank provides a water source for the pressure setting device 100. The water tank is a separate, external unit with a built-in outlet filter. The water tank is connected to the pressure testing platform via a water pipe with quick-connect fittings on both sides. The water tank's outlet line is directly connected to the pump inlet line. Quick-connect fittings at both ends of the high-pressure hose connect it to the pressure testing platform and equipment.

[0104] The compressed air supply device is used to provide an air source for the pressure setting device 100.

[0105] like Figure 18 As shown, an electronic device 200 provided in this embodiment of the invention includes: a processor 201 and a memory 202. The memory 202 stores machine-readable instructions that can be executed by the processor 201. When the machine-readable instructions are executed by the processor 201, the steps in any of the above-described implementations of the pressure setting of the pilot-operated safety valve are executed.

[0106] The above are merely embodiments of the present invention and are not intended to limit the scope of protection of the present invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A pressure setting device for a pilot-operated safety valve, characterized in that, include: Pressure control module, data processing module, and enclosure; The pressure control module is used to provide a controllable hydraulic source to the safety valve under test through the pressure output port; The data processing module is connected to the pressure control module. The data processing module is used to collect the pressure signal from the pressure output port and determine the opening and closing setpoints of the safety valve under test based on the pressure signal. The enclosure houses and integrates the pressure control module and the data processing module, and provides structural support for the oil circuit, air circuit and electrical connection between the pressure control module and the data processing module.

2. The pressure setting device for the pilot-operated safety valve as described in claim 1, characterized in that: The enclosure includes an upper cover, an upper operating table, and a lower storage area; The top cover is detachably mounted on the top of the housing; The upper control panel is located on the upper part of the housing and is used to support the terminal equipment of the data processing module and the operating components of the pressure control module; The lower storage area is located at the bottom of the enclosure and is used to house the pneumatic-driven liquid pump, accumulator, and battery that powers the device of the pressure control module.

3. The pressure setting device for the pilot-operated safety valve as described in claim 1, characterized in that: The enclosure includes a front panel with a main panel and a footstool, and a side panel with slots. The footstool is folded and mounted on the main panel, and the front panel is installed on the front of the housing; or... The main panel is mounted on the side panel by engaging with the slot, and the footstool unfolds to form an angle with the main panel to support the main panel.

4. The pressure setting device for the pilot-operated safety valve as described in claim 2, characterized in that: The enclosure also includes a storage drawer; the storage drawer is located below the upper control panel and is used to store auxiliary components.

5. The pressure setting device for the pilot-operated safety valve as described in claim 1, characterized in that: The pressurization control module includes a pneumatic hydraulic pump, an accumulator, and a regulating valve group with a slow pressurization branch and a slow depressurization branch connected in parallel. The gas-driven liquid pump is used to convert external gas power into hydraulic pressure. The accumulator is connected to the output end of the gas-driven liquid pump via an oil circuit, and is used to store the pressure energy of the liquid pressure. The slow-speed boosting branch connects the accumulator to the pressure output port, and the slow-speed depressurization branch connects the pressure output port to a depressurization port; the regulating valve group is used to regulate the pressure output to the pressure output port based on the pressure energy by controlling the on / off state and opening degree of the slow-speed boosting branch and the slow-speed depressurization branch.

6. The pressure setting device for the pilot-operated safety valve as described in claim 5, characterized in that: The slow boosting branch includes a slow boosting switching valve and a slow boosting regulating valve connected in series. The slow boosting switching valve and the slow boosting regulating valve are used to jointly control the on / off state and flow rate of the slow boosting branch. The slow pressure relief branch includes a slow pressure relief switch valve and a slow pressure relief regulating valve connected in series; the slow pressure relief switch valve and the slow pressure relief regulating valve are used to jointly control the on / off state and flow rate of the slow pressure relief branch.

7. The pressure setting device for the pilot-operated safety valve as described in claim 1, characterized in that: The pressurization control module includes an inflation branch equipped with a check valve; The inflation branch connects an external air source to the pressure output port; The inflation branch is used to provide auxiliary air source pressure to the pressure output port, and the check valve is used to prevent the medium at the pressure output port from flowing back to the external air source.

8. The pressure setting device for the pilot-operated safety valve as described in claim 1, characterized in that: The data processing module includes a pressure transmitter, a data acquisition unit, and a terminal device. The pressure transmitter is connected to the pressure transmitter inlet of the pressure control module. The data acquisition unit is electrically connected to the pressure transmitter and is used to receive pressure signals; The terminal device is communicatively connected to the data acquisition unit, and is used to process the pressure signal, display the pressure curve, and identify the opening and closing points of the safety valve.

9. A pressure setting method for a pilot-operated safety valve, characterized in that, The method, applied to the pressure setting device according to any one of claims 1-8, includes the following steps: The accumulator of the pressure control module is charged with a pressure higher than the expected opening value of the safety valve; The pressure control module is controlled to increase the pressure through the slow boosting branch at a first preset rate until the safety valve opens, and the data processing module monitors and judges to determine the opening set value of the safety valve. The pressure control module is controlled to reduce the pressure through the slow pressure relief branch at a second preset rate until the safety valve closes. The data processing module monitors and judges the pressure to determine the closing set value of the safety valve.

10. A hydraulic testing system, characterized in that, Includes the pressure setting device, water tank, and compressed air supply device as described in any one of claims 1 to 8; The water tank is used to provide a water source for the pressure setting device; The compressed air supply device is used to provide an air source for the pressure setting device.

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