A high-pressure pipeline gas tightness remote automatic detection method

Abstract

The application discloses a kind of high-pressure pipeline gas tightness remote automatic detection method, the high-pressure pipeline gas tightness remote automatic detection method, vacuum pump is connected on the first shunt manifold, and the first shunt manifold is equipped with the test tool, the test tool is connected with the flange node on the second shunt manifold by explosion-proof hose, to make vacuum pump in the closed space formed between flange node and explosion-proof hose negative pressure environment, leaked nitrogen is directed to the nitrogen concentration analyzer at the first shunt manifold and flows to the place;Nitrogen concentration analyzer is connected with the first shunt manifold export, real-time acquisition nitrogen concentration in the drainage gas, and data transmission to pressure test data acquisition device, real-time record each node detection time, nitrogen concentration value, alarm state.The shunt manifold interface of high-pressure pipeline gas tightness remote automatic detection method provided by the application can be flexibly increased or decreased, and the length of hose can be adjusted according to the operation scene, and high-pressure nitrogen pipeline detection can be carried out in different environments.

Description

Technical Field

[0001] This invention belongs to the field of marine engineering and industrial pipeline inspection technology, and particularly relates to a remote automatic inspection method for the airtightness of high-pressure pipelines. Background Technology

[0002] In the construction of high-pressure nitrogen pipelines on offshore platforms and in industrial sectors, airtightness testing is a crucial step in ensuring the safe operation of the pipeline. Traditional high-pressure nitrogen pipeline airtightness testing technologies have long faced the following technical challenges, severely restricting construction efficiency, testing accuracy, and operational safety. These mainly include: Low testing efficiency: Operators need to use the "sprayer leak test" to test each flange node of the pipeline one by one. They need to move the sprayer repeatedly and observe the nodes. If a single pipeline contains more than 10 flange nodes, the testing time usually exceeds 2 hours, which seriously delays the construction progress in multi-node scenarios. Insufficient detection accuracy: Relying on manual observation of bubbles in a spray bottle to determine leak points is easily affected by environmental interference (such as sea breeze, airflow in the workshop causing bubbles to burst, or insufficient light affecting visibility), with a false judgment rate of over 20%, posing a risk of missed detection, which may lead to pipeline leakage accidents later on. Poor operational safety: Operators need to be in close contact with high-pressure pipelines (usually 0.5-1m away from the flange node). If there is a high-pressure nitrogen leak in the pipeline, it may cause personal safety accidents such as gas impact and frostbite. The safety hazards are more prominent, especially in the high-risk operating environment of offshore platforms. Insufficient automation and traceability: Test results need to be recorded manually (such as filling in node numbers, test times, and whether any points were missed in paper ledgers), and data is prone to errors and loss, making it impossible to achieve real-time data upload and traceability; in addition, dedicated personnel are required to continuously monitor and observe, resulting in high labor costs (2-3 people are needed for a single test step).

[0003] Therefore, there is an urgent need to design a remote automatic detection method for the airtightness of high-pressure pipelines to solve the problems mentioned above. Summary of the Invention

[0004] The purpose of this invention is to provide a remote automatic detection method for the airtightness of high-pressure pipelines, which has the advantages of improving detection efficiency, optimizing accuracy, ensuring safety and saving costs, and solves the problems of low efficiency, poor accuracy, insufficient safety and low degree of automation in the traditional high-pressure nitrogen pipeline airtightness detection in the background art.

[0005] To achieve the above objectives, the specific technical solution of the remote automatic detection method for high-pressure pipeline airtightness of the present invention is as follows: A remote automatic detection method for the airtightness of high-pressure pipelines involves connecting a vacuum pump to a first manifold, on which a test fixture is provided. The test fixture is connected to a flange node on a second manifold via an explosion-proof hose, so that the vacuum pump creates a negative pressure environment in the sealed space formed between the flange node and the explosion-proof hose, directing the leaked nitrogen gas to a nitrogen concentration analyzer located in the first manifold. The nitrogen concentration analyzer is connected to the outlet of the first shunt manifold to collect the nitrogen concentration in the diversion gas in real time and transmit the data to the pressure test data acquisition device to record the detection time, nitrogen concentration value and alarm status of each node in real time.

[0006] Furthermore, the inlet of the second manifold is connected to a gas pressurization device, which flows nitrogen gas through the flange node into the tooling to be tested.

[0007] Furthermore, a second shut-off valve is installed on the second diversion manifold, which is located between the flange node and the gas booster.

[0008] Furthermore, a vacuum pump is connected to the inlet of the first shunt manifold, and a test fixture is provided at the outlet of the first shunt manifold.

[0009] Furthermore, a vacuum gauge is connected to the side of the first shunt manifold furthest from the nitrogen concentration analyzer.

[0010] Furthermore, one end of the explosion-proof hose is connected to the flange node via a quick connector.

[0011] Next, start the vacuum pump and open the first shut-off valve of the first shunt manifold to reduce the pressure in the sealed space formed between the flange node and the explosion-proof hose, and maintain the negative pressure for 1-2 minutes.

[0012] Furthermore, after the negative pressure stabilizes, the nitrogen concentration analyzer is activated to monitor the concentration of the drainage gas in real time. If the concentration is ≤80% Vol, the node is considered to have no leakage; If the concentration is >80% Vol, the nitrogen concentration analyzer will trigger an audible and visual alarm and record the node number and alarm time.

[0013] The remote automatic detection method for high-pressure pipeline airtightness of the present invention has the following advantages: (1) The efficiency of the present invention is greatly improved: multi-node synchronous detection combined with automated judgment improves the detection efficiency compared with traditional spray bottle leak detection.

[0014] (2) The detection accuracy of the present invention is optimized: it is automatically determined based on the nitrogen concentration threshold (80% Vol), and is not affected by environmental factors such as airflow and light. The false judgment rate is reduced to a certain level, and the detection process can be traced through data recording to avoid errors caused by manual recording.

[0015] (3) Enhanced operational safety of the invention: Operators can remotely connect to the tooling to be tested through an explosion-proof hose and complete the operation in a data acquisition room far away from high-pressure pipelines, completely avoiding the risk of close contact with high-pressure leakage and eliminating the risk of safety accidents.

[0016] (4) The invention significantly reduces costs: it reduces labor input (only one person is needed to operate a single detection step), thus lowering labor costs; at the same time, it avoids rework costs caused by misjudgment, and the overall cost is lower than that of traditional technologies.

[0017] (5) The invention is highly versatile: the manifold interface can be flexibly increased or decreased to adapt to different numbers of flange nodes; the length of the explosion-proof hose can be adjusted according to the operation scenario, and it is suitable for high-pressure nitrogen pipeline inspection in different environments such as marine platforms and land workshops. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the remote automatic detection method for high-pressure pipeline airtightness according to the present invention.

[0019] Explanation of markings in the diagram: 1. First shunt manifold; 2. Second shunt manifold; 3. Vacuum pump; 4. Test fixture; 5. Explosion-proof hose; 6. Flange joint; 7. Nitrogen concentration analyzer; 8. Gas booster; 9. First shut-off valve; 10. Second shut-off valve; 11. Vacuum pressure gauge. Detailed Implementation

[0020] 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, 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.

[0021] Those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of the invention and form different embodiments. For example, in the claims, any of the claimed embodiments can be used in any combination.

[0022] The following is a reference to the appendix. Figure 1 The present invention describes a remote automatic detection method for the airtightness of high-pressure pipelines.

[0023] like Figure 1As shown, the remote automatic detection method for high-pressure pipeline airtightness in this invention connects a vacuum pump 3 to a first manifold 1. The first manifold 1 is equipped with a test fixture 4, which is connected to a flange node 6 on a second manifold 2 via an explosion-proof hose 5. This allows the vacuum pump 3 to create a negative pressure environment within the sealed space formed between the flange node 6 and the explosion-proof hose 5, directing the leaked nitrogen gas to a nitrogen concentration analyzer 7 located in the first manifold 1. The nitrogen concentration analyzer 7 is connected to the outlet of the first manifold 1, which collects the nitrogen concentration in the diverted gas in real time and transmits the data to a pressure test data acquisition device, recording the detection time, nitrogen concentration value, and alarm status of each node in real time.

[0024] Among them, an explosion-proof vacuum pump 3 is used, which is adapted to the explosion-proof level of the marine platform. Its rated vacuum degree is ≥-0.09MPa. It is connected to the first shunt manifold 1 through a hose. Its function is to create a negative pressure environment in the sealed space formed by the flange node 6 and the explosion-proof hose 5, and to direct the leaked nitrogen to the nitrogen concentration analyzer 7.

[0025] Preferably, both the first diversion manifold 1 and the second diversion manifold 2 are made of stainless steel. The first diversion manifold 1 is provided with multiple test fixtures 4 at intervals, and the second diversion manifold 2 is provided with multiple flange nodes 6.

[0026] Meanwhile, the nitrogen concentration analyzer 7 has a range of 0-100% Vol, an accuracy of ±0.5%, a response time of ≤1s, and is equipped with an audible and visual alarm function (the alarm threshold is set at 80% Vol, which is higher than the basic nitrogen content of 78% in the air, ensuring accurate leak detection); the nitrogen concentration analyzer 7 is connected to the outlet of the first diversion manifold 1 to collect the nitrogen concentration in the diversion gas in real time and transmit the data to the pressure test data acquisition device.

[0027] As a preferred embodiment, the nitrogen concentration analyzer 7 is integrated with the pressure test data acquisition device (including data storage and display functions) and placed in a high-pressure airtight data acquisition room (≥10m away from the test site). The test time, nitrogen concentration value and alarm status of each node are recorded in real time. The data can be exported to the project management system to achieve traceability management.

[0028] Furthermore, such as Figure 1 As shown, the inlet of the second manifold 2 is connected to a gas booster device 8, which flows nitrogen into the test fixture 4 through the flange node 6; the second manifold 2 is equipped with a second shut-off valve 10, which is located between the flange node 6 and the gas booster device 8.

[0029] Preferably, the first diversion manifold 1 is provided with a plurality of first shut-off valves 9, which are spaced apart between the test fixtures 4; the second diversion manifold 2 is provided with a plurality of second shut-off valves 10, which are spaced apart between the flange nodes 6.

[0030] The inlet of the first diversion manifold 1 is connected to the vacuum pump 3, and the multiple test fixtures 4 in the outlet direction are all connected to the flange nodes 6 through explosion-proof hoses 5, so as to realize flexible switching of multi-node test channels.

[0031] Furthermore, such as Figure 1 As shown, a vacuum pump 3 is connected to the inlet of the first shunt manifold 1, and a test fixture 4 is provided at the outlet of the first shunt manifold 1; a vacuum pressure gauge 11 is connected to the side of the first shunt manifold 1 away from the nitrogen concentration analyzer 7, and the overall negative pressure environment is detected by the vacuum pressure gauge 11.

[0032] As a preferred embodiment, the operation steps of the remote automatic detection method for the airtightness of high-pressure pipelines are as follows: S1. Preparations before construction: Confirm that the first branch manifold 1 has been depressurized to a safe pressure (≤0.1MPa). Connect one end of the explosion-proof hose 5 to the flange node 6 through a quick connector and ensure that the interface is sealed (the hose sealing can be initially checked with soapy water). Among them, according to the number of flange nodes, a corresponding number of explosion-proof hoses 5 are installed on the second branch manifold 2, and all second shut-off valves 10 are closed; S2. Negative pressure environment construction: Start vacuum pump 3, open the first shut-off valve 9 corresponding to the test fixture 4 of the first shunt manifold 1, so that the pressure in the sealed space formed by flange node 6 and explosion-proof hose 5 drops to -0.06~-0.08MPa (monitored by vacuum pump pressure gauge), and maintain the negative pressure for 1-2 minutes. S3. Nitrogen Concentration Detection: After the negative pressure stabilizes, start the nitrogen concentration analyzer 7 to monitor the concentration of the drainage gas in real time. If the concentration is ≤80% Vol, it is determined that there is no leakage at this node. Close the first shut-off valve 9 corresponding to the current test fixture 4, and open the first shut-off valve 9 corresponding to the next test fixture 4 to continue the test. If the concentration is >80% Vol, the nitrogen concentration analyzer 7 will trigger an audible and visual alarm, record the number of the test fixture 4 and the alarm time, and notify the on-site personnel to check for leaks (such as damaged flange gaskets, loose bolts, etc.). S4. Multi-node synchronous detection: Through the multi-interface design of the first shunt manifold 1, the first shut-off valve 9 corresponding to 2-4 test fixtures 4 can be opened simultaneously (adapted according to the vacuum pump power), realizing the parallel detection of multiple test fixtures 4. During the detection process, the concentration data of each node is distinguished in real time through the data integration module (the node number is marked). S5. Data Recording and Closure: After all the test fixtures 4 have been tested, export the test records (including node number, test time, concentration value, and judgment result) from the data integration module, turn off the vacuum pump 3 and nitrogen concentration analyzer 7, remove the explosion-proof hose 5 and the second shunt manifold 2, and tidy up the test fixtures 4.

[0033] Based on the remote automatic detection method for the airtightness of high-pressure pipelines, this invention reduces labor costs and avoids rework costs caused by misjudgment, resulting in a lower overall cost compared to traditional technologies.

[0034] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A remote automatic detection method for the airtightness of high-pressure pipelines, characterized in that, A vacuum pump is connected to the first manifold, which is equipped with a test fixture. The test fixture is connected to the flange node on the second manifold via an explosion-proof hose, so that the vacuum pump creates a negative pressure environment in the sealed space between the flange node and the explosion-proof hose, and directs the leaked nitrogen to the nitrogen concentration analyzer located in the first manifold. The nitrogen concentration analyzer is connected to the outlet of the first shunt manifold to collect the nitrogen concentration in the diversion gas in real time and transmit the data to the pressure test data acquisition device to record the detection time, nitrogen concentration value and alarm status of each node in real time.

2. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 1, characterized in that, The inlet of the second manifold is connected to a gas pressurization device, which flows nitrogen gas through the flange node into the test fixture.

3. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 2, characterized in that, The second branch manifold is equipped with a second shut-off valve, which is located between the flange node and the gas booster.

4. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 1, characterized in that, The inlet of the first manifold is connected to a vacuum pump, and the outlet of the first manifold is equipped with a test fixture.

5. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 4, characterized in that, A vacuum gauge is connected to the side of the first shunt manifold furthest from the nitrogen concentration analyzer.

6. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 1, characterized in that, One end of the explosion-proof hose is connected to the flange joint via a quick connector.

7. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 1, characterized in that, Start the vacuum pump and open the first shut-off valve of the first manifold to reduce the pressure in the sealed space formed between the flange node and the explosion-proof hose, and maintain the negative pressure for 1-2 minutes.

8. The remote automatic detection method for the airtightness of high-pressure pipelines according to claim 7, characterized in that, After the negative pressure stabilizes, start the nitrogen concentration analyzer to monitor the concentration of the drainage gas in real time. If the concentration is ≤80% Vol, the node is considered to have no leakage; If the concentration is >80% Vol, the nitrogen concentration analyzer will trigger an audible and visual alarm and record the node number and alarm time.

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