Safety valve automatic calibration method and safety valve automatic calibration device

Abstract

The application discloses a kind of safety valve automatic calibration method and safety valve automatic calibration device, safety valve automatic calibration method includes control system according to the preset setting pressure of safety valve to be detected, automatically judges and opens the passage valve of adaptive range;Control system controls calibration valve to open and carries out staged automatic pressure rise;Pressure rises to safety valve to be detected to open, first pressure sensor gathers current pressure as setting pressure measured value, while control system closes calibration valve in time when safety valve to be detected opens;Control system judges whether the opening pressure of safety valve to be detected is qualified according to setting pressure measured value;If qualified, repeat opening pressure calibration multiple times, if multiple times are qualified, then calibration is passed, if any time is unqualified, then calibration is terminated, and safety valve opening pressure calibration is not passed.The application can not only eliminate pressure overshoot error and accidental measurement error, realize the full-process automation of calibration without human intervention, but also can avoid the damage of safety valve sealing surface caused by too fast pressure rise.

Description

Technical Field

[0001] This invention relates to the field of safety valve calibration technology, specifically to an automatic safety valve calibration method and an automatic safety valve calibration device. Background Technology

[0002] As a core safety accessory for pressure-bearing equipment, the accuracy of the opening pressure and the reliability of the seal directly affect the operational safety of the equipment and the safety of personnel and property. Regular calibration is necessary to ensure performance meets standards. Existing safety valve calibration methods can collect, record, and generate reports, simplifying the calibration process to some extent. However, these devices still have core drawbacks: First, they use a single-rate pressurization without phased, precise control, making them prone to pressure overshoot, leading to deviations in the valve's tripping point judgment, and excessively rapid pressurization can damage the valve's sealing surface. Second, they can only perform single-test calibrations, lacking a mechanism for multiple repetitions, resulting in insufficient reliability. Third, existing control mechanisms can only collect and record data, unable to automatically switch pressurization rates or implement multiple calibration cycles, requiring manual intervention and failing to achieve full automation. Therefore, there is an urgent need for a technical solution that relies on precise automatic control to achieve phased pressurization and multiple set pressure calibrations, addressing the problems of low accuracy, poor reliability, and easy damage to safety valves in existing technologies. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides an automatic safety valve calibration method and device, which enables automatic calibration through staged pressure increase and multiple pressure setting. This eliminates pressure overshoot errors and accidental measurement errors, achieves fully automated calibration without human intervention, and avoids damage to the safety valve sealing surface due to excessively rapid pressure increase, thereby improving calibration accuracy, efficiency, and reliability.

[0004] The specific technical solution provided by this invention is as follows: Firstly, an automatic calibration method for a safety valve is provided, including an opening pressure calibration method, which includes the following steps: S1: The control system automatically determines and opens the channel valve with the appropriate range based on the preset set pressure of the safety valve under test. The channel valve is connected to the safety valve under test, the control system and the first pressure sensor. S2: The control system controls the opening of the verification valve and performs automatic pressure increase in stages. The verification valve is connected to the gas source, the safety valve to be tested, and the control system. S3: The pressure is increased until the safety valve to be tested opens. The first pressure sensor collects the current pressure as the measured value of the set pressure. At the same time, the control system closes the verification valve in time when the safety valve to be tested opens. S4: The control system controls the pressure relief of the safety valve under test and judges whether the opening pressure of the safety valve under test is qualified based on the actual measured value of the set pressure. S5: If it fails, the verification is terminated and the safety valve opening pressure verification fails. If it passes, the safety valve to be tested is closed and steps S2 to S4 are repeated multiple times to perform multiple opening pressure verifications. If the safety valve to be tested is found to be qualified in all multiple opening pressure verifications, the safety valve opening pressure verification passes. If the safety valve to be tested is found to be unqualified in any of the multiple opening pressure verifications, the verification is terminated and the safety valve opening pressure verification fails.

[0005] As a preferred embodiment of the above scheme, S2 includes: The control system controls the verification valve to fully open for the first stage of pressurization, and uses the first pressurization rate to increase the pressure. The control system adjusts the calibration valve to 90% opening for the second stage of pressurization, and uses a second pressurization rate that is lower than the first pressurization rate.

[0006] As a preferred embodiment of the above scheme, in the phased automatic pressurization process, the first pressure sensor collects the real-time pressure. During the first stage of pressurization, the real-time pressure is lower than 90% of the preset set pressure, and the first pressurization rate is 0.5MPa / min-10MPa / min. When the real-time pressure reaches 90% of the preset set pressure, the control system controls the verification valve to adjust to 90% opening for the second stage of pressure increase to continue increasing the pressure until the safety valve to be tested opens, and the second pressure increase rate is less than 0.6MPa / min.

[0007] As a preferred embodiment of the above scheme, in S3, the first pressure sensor collects the current pressure, and the control system records the current pressure as the measured value of the set pressure. In S4, determining whether the opening pressure of the safety valve under test is qualified based on the measured value of the set pressure includes: If the measured value of the set pressure is within the acceptable deviation range of the preset set pressure, then the opening pressure of the safety valve under test is qualified; otherwise, the opening pressure of the safety valve under test is unqualified.

[0008] As a preferred embodiment of the above scheme, in S5, when the safety valve opening pressure verification fails, the control system records the data during the verification process and records the reason for the failure of the safety valve opening pressure according to the measured value of the set pressure and the preset set pressure.

[0009] As a preferred embodiment of the above scheme, in S4, the control system controls the pressure relief of the safety valve under test, including: The control system controls the pressure relief valve to open and release pressure. When the real-time pressure collected by the first pressure sensor drops to a preset range, the control system controls the pressure relief valve to close. The pressure relief valve is connected to the safety valve under test.

[0010] As a preferred embodiment of the above scheme, after the safety valve opening pressure test is passed, the automatic safety valve calibration method also includes a sealing pressure calibration method, which includes: The control system automatically determines and opens the channel valve with the appropriate range based on the preset sealing pressure of the safety valve under test. The channel valve is connected to the safety valve under test, the control system, and the first pressure sensor. The control system controls the opening of the calibration valve to automatically increase the pressure. The first pressure sensor collects the real-time pressure. The calibration valve is connected to the air source, the safety valve to be tested, and the control system. When the real-time pressure reaches the preset sealing pressure, the control system controls the verification valve to close, and the safety valve under test maintains a sealing pressure for a period of time. After sealing and pressurizing, the control system calculates the pressure drop during the sealing and pressurizing process based on the current real-time pressure and the initial pressure holding time. If the pressure drop is within the preset allowable range, the safety valve sealing pressure test passes; otherwise, the safety valve sealing pressure test fails.

[0011] As a preferred embodiment of the above scheme, the preset sealing pressure is 90% of the preset set pressure; The control system controls the verification valve to fully open for automatic pressure increase, and increases the pressure at a rate of 0.5MPa / min-10MPa / min.

[0012] Secondly, an automatic safety valve calibration device is provided for performing the above-described automatic safety valve calibration method. The device includes a gas source mechanism, a clamping mechanism, multiple channel valves with different ranges, a first pressure sensor, and a control system. The gas source mechanism is used to provide a gas source and includes a calibration valve. The clamping mechanism is used to clamp the safety valve to be tested. The gas source mechanism, clamping mechanism, and channel valves are connected through a gas circuit. The gas source mechanism, clamping mechanism, channel valves, and first pressure sensor are communicatively connected to the control system. The control system can control the calibration valve to achieve different opening degree adjustments.

[0013] As a preferred embodiment of the above solution, the clamping mechanism includes a clamping platform and multiple jaws. The clamping platform is provided with a central hole and multiple evenly distributed first slots, and the jaws are slidably disposed on the first slots. The clamping platform is also provided with a second slot located between the adjacent first slots, and the safety valve to be inspected is clamped in the center hole by the claws; The jaws are removed from the first slot and assembled into the second slot. The jaws on the second slot and the remaining jaws on the first slots cooperate to clamp irregularly shaped safety valves to be inspected. The chuck has a first chuck protrusion and a second chuck protrusion distributed vertically, and both the first chuck protrusion and the second chuck protrusion have slots.

[0014] This invention controls the opening of the verification valve through a control system and performs automatic pressure increase in stages. This avoids pressure overshoot caused by a single rate of pressure increase in the verification valve, so that when the safety valve under test opens, the control system can react in time to close the verification valve. At the same time, it can avoid damage to the sealing surface of the safety valve by excessively rapid pressure increase. By performing multiple opening pressure verifications, it can avoid the random errors caused by a single verification, thereby improving the verification accuracy and reliability. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 A flowchart of the pressure verification method provided in an embodiment of the present invention; Figure 2 A flowchart of the sealing pressure verification method provided in the embodiments of the present invention; Figure 3 This is a schematic diagram of the structure of the automatic safety valve calibration device provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the opening structure of the calibration valve provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the opening structure of the calibration valve provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the clamping mechanism provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the clamping stage provided in an embodiment of the present invention; Figure 8 This is a schematic diagram of the gripper structure provided in an embodiment of the present invention; Figure 9 for Figure 8 A top-view structural diagram; Figure 10 for Figure 8 A side view structural diagram.

[0017] The above figures include the following reference numerals: Air source mechanism 1; Calibration valve 11; First open / closed state 101; Second open / closed state 102; Third open / closed state 103; Inlet / exhaust port 111; Inlet / exhaust valve 112; Fixed pressure reducing valve 113; Purge gun 114; Manual calibration valve 115; Air source unit 12; Compressed air cylinder 13; Inlet valve 14; Pressure reducing valve 15; Air source main control valve 16; Pressure relief valve 17; Manual vent valve 171; Pressure gauge before pressure reduction 18; Pressure gauge after pressure reduction 19; Clamping mechanism 2; Channel valve 3; First channel valve 31; Pressure gauge 311 (0-1.6 MPa pressure rating); Second channel valve 32; Pressure gauge 321 (0-4 MPa pressure rating); Third channel valve 32; Valve 33; Pressure gauge 331 (0-16 MPa pressure rating); Fourth channel valve 34; Pressure gauge 341 (0-40 MPa pressure rating); Manual valve 35; First pressure sensor 4; Hydraulic unit 5; Hydraulic pump 51; Hydraulic cylinder 52; Push rod 53; Air port 531; Pressure boosting hydraulic pipe 54; Pressure return hydraulic pipe 55; Pressure boosting sensor 56; Pressure return sensor 57; Pressure boosting solenoid valve 58; Pressure return solenoid valve 59; Fixing unit 6; Clamping platform 61; Center hole 611; First slot 612; Second slot 613; Claw 62; First protrusion 621; Second protrusion 622; Slot 623; Flange connecting plate 63. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0019] It should be noted that when an element is described as "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as "connected to" another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "vertical," "horizontal," "left," "right," "upper," "lower," "inner," "outer," "bottom," etc., used in this specification indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] As described in the background section, safety valves, as core safety accessories for pressure-bearing equipment, directly affect the operational safety of the equipment and the safety of personnel and property through their opening pressure accuracy and sealing reliability. Regular calibration is necessary to ensure performance meets standards. Currently, some automatic safety valve calibration devices exist that can achieve real-time acquisition, recording, and calibration report generation of pressure data, simplifying the calibration process and improving its convenience to some extent.

[0021] However, existing technologies and similar automatic calibration devices still have core technical defects, failing to meet the high-precision and high-reliability calibration requirements of modern industry, and are prone to damaging safety valves: First, existing automatic calibration devices use a single-rate pressurization mode without phased and precise pressurization control, which easily leads to pressure overshoot, causing deviations in the safety valve's tripping point judgment, affecting the accuracy of the set pressure measurement. Furthermore, excessively rapid pressurization can impact the safety valve's sealing surface, causing damage and shortening its service life. Second, existing automatic calibration devices can only perform single-stage set pressure calibration, lacking a mechanism for multiple repeated calibrations, making the calibration results susceptible to random errors and insufficient reliability. Third, the control systems of existing devices can only collect and record pressure data, unable to achieve precise switching of pressurization rates and automatic cycling of multiple calibrations through automatic control. Manual intervention is still required in some processes, failing to achieve fully automated calibration. To address these shortcomings of existing technologies, a technical solution relying on precise automatic control to achieve phased pressurization and multiple set pressure calibrations is urgently needed to solve the problems of low accuracy, poor reliability, and easy damage to safety valves in existing automatic calibration devices.

[0022] This invention enables precise control of the calibration valve, achieving phased pressure increase and three automatic calibrations of the set pressure. It can eliminate pressure overshoot errors and accidental measurement errors, realize unattended automation of the entire calibration process, and avoid damage to the safety valve sealing surface due to excessively rapid pressure increase. This improves calibration accuracy, efficiency and reliability, protects safety valve components, and reduces maintenance costs and operational barriers.

[0023] Example 1 This invention provides an automatic calibration method for a safety valve, including an opening pressure calibration method, such as... Figure 1 As shown, the method for enabling pressure verification includes the following steps: S1: The control system automatically determines and opens the channel valve 3 with the appropriate range according to the preset set pressure of the safety valve under test. The channel valve 3 is connected to the safety valve under test, the control system and the first pressure sensor 4.

[0024] The control system may include a data acquisition system, a data analysis system, and a data control system. The data acquisition system can be a computer-based system, connected to detection elements such as the first pressure sensor 4, to collect pressure data (such as measured values ​​of boost pressure, set pressure, and sealing pressure) and safety valve opening curve data in real time during the calibration process. The high acquisition frequency ensures data continuity and accuracy. The data analysis system can be a computer-based PLC system, receiving real-time data from the data acquisition system, processing and analyzing the data, including calculating the average measured set pressure, determining the safety valve opening status, analyzing pressure change trends during the sealing pressure holding process, analyzing the opening degree of calibration valve 11, and storing historical calibration data, supporting data traceability and export.

[0025] The data control system can be a computer PLC data control system, which includes a PLC execution module (including digital output module and analog output module), a drive circuit (used to control the verification valve 11, pressure relief valve 17, and channel valve 3) and an emergency stop unit (with dual protection of hardware emergency stop button and software emergency stop command). The data control system receives instructions from the data analysis system and precisely controls the actions of each actuator. The core control logic includes: automatically switching the corresponding channel valve 3 according to the preset set pressure of the safety valve under test to ensure pressure control accuracy and adaptive switching; control of the opening of the calibration valve 11: sending a 0-10V analog signal (corresponding to the valve opening of 0-100%) to the calibration valve 11 through the analog output module to achieve continuous adjustment of the opening and meet the staged pressure increase requirements; process timing control: strictly controlling the actions of each valve according to the timing sequence of "pressure increase-pressure holding-pressure release". For example, during the sealing pressure test, first control the calibration valve 11 to open and increase the pressure to the target value, then close the calibration valve 11 to hold the pressure, and after the pressure holding is completed, control the pressure release valve 17 to open and release the pressure. The time deviation of each step is ≤0.5s.

[0026] Furthermore, the aforementioned data acquisition system, data analysis system, and data control system can be integrated into a control cabinet with a human-machine interface module. The control cabinet is equipped with a console with a display, operation buttons and switches, wiring terminals or interfaces, and pressure gauges. Operators can select the "Automatic Calibration" option on the display's calibration interface and then click the "Set Pressure Calibration" button. The data control system receives the start command and begins executing the automatic calibration process.

[0027] Operators can input basic information (including model, nominal diameter, rated pressure, preset set pressure, preset sealing pressure, etc.) and verification parameters (staged pressure increase rate, verification valve 11 opening degree, number of verifications, acceptable deviation range, pressure relief control parameters, etc.) of the safety valve to be inspected into the data control system through the human-machine interface module. The pressure relief control parameter is set to close the pressure relief valve 17 when the pressure drops below 0.1 MPa and approaches zero, ensuring the reliability of the verification results. After receiving the start signal, the data control system initiates initialization, checks the operating status of each module, alarms and terminates the process if abnormal, and proceeds to the next step if normal. Before opening the channel valve 3 with the appropriate range, the safety valve to be inspected also needs to be clamped and positioned by the clamping mechanism 2.

[0028] The data control system connects multiple channel valves 3 with different ranges. Channel valves 3 are connected to the safety valve under test via air circuits. Channel valves 3 can be high-pressure electromagnetic channel valves. For example, a first channel valve 31 corresponds to the 0-1.6MPa range, a second channel valve 32 corresponds to the 0-4MPa range, a third channel valve 33 corresponds to the 0-16MPa range, and a fourth channel valve 34 corresponds to the 0-40MPa range. The first channel valve 31 is used to test safety valves with a 0-1.6MPa pressure (e.g., a safety valve with a preset set pressure of 1MPa), the first channel valve 31 is used to test safety valves with a 0-4MPa pressure (e.g., a safety valve with a preset set pressure of 3MPa), the third channel valve 33 is used to test safety valves with a 0-16MPa pressure (e.g., a safety valve with a preset set pressure of 10MPa), and the fourth channel valve 34 is used to test safety valves with a 0-40MPa pressure (e.g., a safety valve with a preset set pressure of 20MPa). The data control system automatically controls the four channel valves 3 to switch to the appropriate pressure range according to the preset set pressure, ensuring accurate pressure acquisition and avoiding measurement errors caused by range mismatch. Unlike existing technologies that require manual switching of the range cut-off switch, this step achieves automatic range adaptation and improves the convenience of operation.

[0029] like Figure 3As shown, the four channel valves 3 are respectively connected to the first pressure sensor 4 of the corresponding range, and each of the four channel valves 3 can be connected to a channel manual valve 35 to serve as an emergency backup valve in case of a channel valve 3 failure. The four channel valves 3 can be connected to pressure gauges of four different ranges: the first channel valve 31 connects to a pressure gauge 311 with a pressure rating of 0-1.6 MPa to calibrate the safety valve at 0-1.6 MPa; the second channel valve 32 connects to a pressure gauge 321 with a pressure rating of 0-4 MPa to calibrate the safety valve at 0-4 MPa; the third channel valve 33 connects to a pressure gauge 331 with a pressure rating of 0-16 MPa to calibrate the safety valve at 0-16 MPa; and the fourth channel valve 34 connects to a pressure gauge 341 with a pressure rating of 0-40 MPa to calibrate the safety valve at 0-40 MPa. To enhance the reliability of the pressure gauge readings, each range of pressure gauge can be equipped with two gauges connected in parallel, corresponding to the first pressure sensor 4 of each of the four ranges, forming a parallel connection between the corresponding pressure gauge and the first pressure sensor 4. The pressure gauge can be installed at the top of the control cabinet so that its surface is parallel to the operator's line of sight, making it convenient for the operator to read the pressure gauge.

[0030] S2: The control system controls the opening of the calibration valve 11 and performs automatic pressure increase in stages. The calibration valve 11 is connected to the gas source, the safety valve to be tested, and the control system.

[0031] like Figure 3 As shown, the calibration valve 11 can be an electrically operated calibration valve 11, and the electrically operated calibration valve 11 can be connected in parallel with a manually operated calibration valve 115 as an emergency backup. The calibration valve 11 is part of the gas source mechanism 1, which provides a high-pressure gas source. The calibration valve 11 is connected to the high-pressure gas source and the safety valve to be tested via a gas circuit, and the calibration valve 11 is communicatively connected to the data control system. The gas source mechanism 1 may include a pressure buffer tank, through which the high-pressure gas source supplies pressure to the inlet side of the safety valve, increasing the pressure in stages according to a preset rate and the opening degree of the calibration valve 11.

[0032] The data control system controls the verification valve 11 to fully open for the first stage of pressurization, and adopts a relatively fast pressurization rate of 0.5MPa / min-10MPa / min to improve verification efficiency. For example, it can be 0.8MPa / min. During the staged automatic pressurization, the first pressure sensor 4 collects the real-time pressure. During the first stage of pressurization, the real-time pressure is lower than 90% of the preset set pressure.

[0033] When the real-time pressure reaches 90% of the preset set pressure, the data control system adjusts the verification valve 11 to 90% opening for a second stage of pressure increase to continue increasing the pressure until the safety valve under test opens. A slower pressure increase rate is used to avoid pressure overshoot that could cause the data control system to misjudge the safety valve's tripping point. The second pressure increase rate is lower than the first pressure increase rate, and is less than 0.6 MPa / min; for example, it can be 0.4 MPa / min. Figure 4 , Figure 5 As shown, the opening degree of the verification valve 11 can be adjusted using a motor or cylinder during the above process. The data control system adjusts the opening degree of the verification valve 11 by controlling the output shaft of the motor or cylinder. The first opening / closing state 101 indicates that the verification valve 11 is completely closed, the second opening / closing state 102 indicates that the verification valve 11 is 90% open, and the third opening / closing state 103 indicates that the verification valve 11 is fully open.

[0034] Through the automatic pressurization in the two stages described above, the data control system can close the calibration valve 11 in a timely manner. This not only avoids pressure overshoot that could lead to a deviation in the judgment of the safety valve's opening point, ensuring that the system can accurately capture the safety valve's opening pressure, but also prevents excessively rapid pressurization from impacting the safety valve's sealing surface and causing damage to it. At the same time, the slow pressurization also ensures that the operator can read the pressure gauge.

[0035] S3: The pressure is increased until the safety valve to be tested opens. The first pressure sensor 4 collects the current pressure as the measured value of the set pressure. At the same time, the control system closes the verification valve 11 in time when the safety valve to be tested opens.

[0036] Specifically, when the data acquisition system detects that the safety valve is open (determined by detecting a sudden pressure drop through the first pressure sensor 4), the data control system immediately records the current pressure value as the measured value of the set pressure.

[0037] The control system quickly closes the calibration valve 11 when the safety valve under test is opened, which can prevent the pressure from continuously rising and pressure overshoot, ensuring that the data control system accurately captures the actual opening pressure of the safety valve and eliminates the deviation in the start point judgment caused by pressure overshoot.

[0038] S4: The control system controls the pressure relief of the safety valve under test and determines whether the opening pressure of the safety valve under test is qualified based on the actual measured value of the set pressure.

[0039] Specifically, the control system controls the pressure relief of the safety valve under test, including: like Figure 3 As shown, the data control system controls the pressure relief valve 17 to open for pressure relief. When the real-time pressure collected by the first pressure sensor 4 drops to the preset range, the control system controls the pressure relief valve 17 to close. The pressure relief valve 17 is connected to the safety valve to be tested.

[0040] like Figure 3 As shown, the pressure relief valve 17 can be a high-pressure solenoid vent valve, which can be connected in parallel with the manual vent valve 171. The pressure relief valve 17 is connected to the safety valve under test via a pneumatic circuit. The data control system automatically opens the high-pressure vent solenoid valve to relieve pressure; when the pressure drops below 0.1 MPa and approaches zero, the data acquisition system sends a signal to the data control system, which then automatically closes the high-pressure vent solenoid valve.

[0041] Determining whether the opening pressure of the safety valve under test is qualified based on the actual measured value of the set pressure includes: If the measured value of the set pressure calculated by the data control system is within the acceptable deviation range of the preset set pressure, then the opening pressure of the safety valve under test is qualified; otherwise, the opening pressure of the safety valve under test is unqualified. The acceptable deviation range can be ±5% of the preset set pressure, and can be preset according to industry standards or user requirements.

[0042] S5: If it fails, the verification is terminated and the safety valve opening pressure verification fails. If it passes, the safety valve to be tested is closed and steps S2 to S4 are repeated multiple times to perform multiple opening pressure verifications. If the safety valve to be tested is found to be qualified in all multiple opening pressure verifications, the safety valve opening pressure verification passes. If the safety valve to be tested is found to be unqualified in any of the multiple opening pressure verifications, the verification is terminated and the safety valve opening pressure verification fails.

[0043] The default number of successful verifications is set to 3. During the first pressure verification, if the measured value of the set pressure is within the acceptable deviation range of the preset set pressure, it is considered a successful first reading. The data control system automatically opens the high-pressure venting solenoid valve to release pressure. When the pressure drops below 0.1 MPa and approaches zero, the data acquisition system sends a signal to the data control system, automatically closing the high-pressure venting solenoid valve and initiating the second automatic pressure verification. The measured value of the second set pressure is recorded. If the measured value of the second set pressure is still within the acceptable range, it is considered a successful second reading, and the system automatically releases pressure again. After pressure release, the system automatically initiates the third pressure verification, following the same procedure, and records the measured value of the third set pressure. If the measured value of the third set pressure is acceptable, the pressure verification is considered successful, and the system proceeds to the sealing pressure verification stage.

[0044] When the safety valve fails the opening pressure test, the control system records the data during the test and records the reason for the failure based on the measured value of the set pressure and the preset set pressure. Specifically, if any of the measured values ​​of the set pressure exceeds the acceptable range, the data analysis system immediately determines that the safety valve's opening pressure is unacceptable, sends a command to the data control system to terminate the subsequent test process (no more remaining opening pressure or sealing pressure tests), and displays a "Opening pressure unacceptable" message on the control cabinet's test interface, while recording the unacceptable data and the reason.

[0045] After the safety valve opens and passes the pressure test, the automatic safety valve calibration method also includes a sealing pressure test method, such as... Figure 2 As shown, the sealing pressure verification method includes: S6: The control system automatically determines and opens the channel valve 3 with the appropriate range based on the preset sealing pressure of the safety valve under test. The channel valve 3 is connected to the safety valve under test, the control system and the first pressure sensor 4.

[0046] The preset sealing pressure is generally 90% of the preset set pressure. The operator clicks the "Sealing Pressure Test" button on the verification interface to automatically start the sealing pressure verification process.

[0047] S7: The control system controls the opening of the verification valve 11 to automatically increase the pressure. The first pressure sensor 4 collects the real-time pressure. The verification valve 11 is connected to the air source, the safety valve to be tested, and the control system.

[0048] Specifically, the data control system controls the verification valve 11 to be fully opened for automatic pressure increase, and uses a pressure increase rate of 0.5MPa / min-10MPa / min to avoid damage to the sealing surface of the safety valve due to excessive pressure increase.

[0049] S8: When the real-time pressure reaches the preset sealing pressure, the control system controls the verification valve 11 to close, and the safety valve to be tested will be sealed and pressure maintained for a period of time.

[0050] Specifically, when the real-time pressure reaches the preset sealing pressure, the data acquisition system sends a signal to the data control system, which then controls the verification valve 11 to close and begins the sealing and pressure holding test. The pressure holding time can be set to 3 minutes, and the time can be preset and adjusted through the software in the data control system.

[0051] S9: After sealing and pressurizing, the control system calculates the pressure drop during the sealing and pressurizing process based on the current real-time pressure and the initial pressure of pressurizing.

[0052] After the pressure holding time is over, the data acquisition system records the real-time pressure value, which is the pressure value at the end of the pressure holding process, and the data analysis system calculates the pressure drop during the pressure holding process, which is the difference between the pressure at the beginning and the pressure at the end of the pressure holding process.

[0053] S10: If the pressure drop is within the preset allowable range, the seal pressure verification of the safety valve passes; otherwise, the seal pressure verification of the safety valve fails.

[0054] Specifically, if the pressure drop is less than or equal to the preset allowable pressure drop, the seal pressure is determined to be qualified. After the seal pressure verification is completed, the measured values of the opening pressure three-stage setting pressure and the measured seal pressure are displayed on the verification interface of the control cabinet, and a verification report (including safety valve information, verification data, and qualified determination results) is generated, supporting PDF format export or printing, and the safety valve verification certificate is printed by laser at one key. If the pressure drop is greater than the preset allowable pressure drop, the seal pressure is determined to be unqualified. At the same time, the data control system records the unqualified data and reasons and displays them on the verification interface.

[0055] After the automatic verification of the safety valve ends and the pressure of the entire gas circuit is relieved to atmospheric pressure, the operator removes the safety valve, and the data control system controls each module and component to reset and waits for the next verification.

[0056] In the present invention, the control system controls the opening of the check valve 11 and performs staged automatic pressure boosting, thereby avoiding the pressure overshoot caused by the single-rate pressure boosting of the check valve 11, so that when the to-be-tested safety valve jumps and opens, the control system can react in time to close the check valve 11, and at the same time, it can avoid damaging the sealing surface of the safety valve due to too fast pressure boosting; by performing multiple opening pressure verifications, the accidental errors generated by single verification can be avoided, and the verification accuracy and reliability can be improved.

[0057] Embodiment 2 The present invention provides a safety valve automatic verification device for performing the safety valve automatic verification method of Embodiment 1, as Figure 3 shown, including a gas source mechanism 1, a clamping mechanism 2, multiple channel valves 3 with different ranges, a first pressure sensor 4, and a control system (not shown). The gas source mechanism 1 is used to provide a gas source and includes a check valve 11. The clamping mechanism 2 is used to clamp the to-be-tested safety valve. The gas source mechanism 1, the clamping mechanism 2, and the channel valve 3 are connected through a gas circuit. The gas source mechanism 1, the clamping mechanism 2, the channel valve 3, and the first pressure sensor 4 are communicatively connected to the control system, and the control system can control the check valve 11 to achieve different opening degree adjustments.

[0058] As Figure 3 shown, the gas source mechanism 1 includes a gas source machine 12, a compressed air bottle 13, an intake valve 14, a pressure reducing valve 15, a gas source master control valve 16, a pressure relief valve 17, and a check valve 11 connected through a gas circuit, as well as a pressure gauge 18 before decompression connected to the intake valve 14 and a pressure gauge 19 after decompression connected to the pressure reducing valve 15. The gas source mechanism 1 further includes an air inlet and outlet 111, an air inlet and outlet valve 112, a constant pressure reducing valve 113, and a purging gun 114 connected to the check valve 11 through a gas circuit.

[0059] like Figure 6 As shown, the clamping mechanism 2 includes a hydraulic unit 5 and a fixing unit 6 that cooperates with the hydraulic unit 5 to clamp the safety valve to be inspected. The hydraulic unit 5 is connected to the data control system and can adjust the clamping force according to the safety valve's diameter and pressure level. The hydraulic unit 5 includes a hydraulic pump 51, a hydraulic cylinder 52, a push rod 53, a boost hydraulic pipe 54, a return hydraulic pipe 55, a boost pressure sensor 56, a return pressure sensor 57, a boost solenoid valve 58, and a return solenoid valve 59. The push rod 53 is connected to the piston of the hydraulic cylinder 52 and has an air hole 531 for the passage of test gas. The hydraulic cylinder 52 drives the push rod 53 to move up and down under the drive of the electric hydraulic pump 51. Hydraulic pump 51 is connected to hydraulic cylinder 52 via pressure boosting solenoid valve 58 and pressure boosting hydraulic pipe 54. Hydraulic pump 51 is also connected to hydraulic cylinder 52 via return pressure solenoid valve 59 and return pressure hydraulic pipe 55. Pressure boosting sensor 56 is connected to pressure boosting solenoid valve 58, and return pressure sensor 57 is connected to return pressure solenoid valve 59. Pressure boosting sensor 56, return pressure sensor 57, pressure boosting solenoid valve 58, and return pressure solenoid valve 59 are communicatively connected to data acquisition and data control systems to achieve data acquisition and automatic adjustment of clamping pressure.

[0060] like Figure 7 As shown, the fixing unit 6 includes a clamping platform 61 and multiple jaws 62. The clamping platform 61 has a central hole 611 and multiple evenly distributed first slots 612, with the jaws 62 slidably mounted on the first slots 612. The clamping platform 61 also has second slots 613 located between adjacent first slots 612. The safety valve to be inspected is clamped by the jaws 62 at the central hole 611. The jaws 62 can be detached from one of the first slots 612 and assembled into the second slot 613. The jaws 62 on the second slot 613 cooperate with the jaws 62 on the remaining first slots 612 to clamp irregularly shaped safety valves to be inspected. For example, for a pilot-operated safety valve with a pipe near the flange, the jaws 62 on the second slot 613 can avoid the pipe to achieve stable clamping of the pilot-operated safety valve.

[0061] In one implementation, such as Figure 7 As shown, the clamping platform 61 is circular, and has three first slots 612 radially distributed along it. The included angle between adjacent first slots 612 is 120 degrees. The included angle between the second slot 613 and the adjacent first slot 612 is 60 degrees. One end of the first slot 612 and the second slot 613 communicates with the central hole 611, and the other end passes through the circumferential sidewall of the clamping platform 61.

[0062] like Figure 8As shown, the upper part of the jaw 62 facing the central hole 611 has a first locking protrusion 621, and the side facing away from the central hole 611 has a second locking protrusion 622. The second locking protrusion 622 is located below the first locking protrusion 621. A slot 623 is formed in the middle of the second locking protrusion 622 and the first locking protrusion 621. When clamping a safety valve with a pipe near the flange, such as a pilot-operated safety valve, the slot 623 can be used to avoid the pipe near the flange during clamping, making clamping easier. By setting the first locking protrusion 621 and the second locking protrusion 622 at different heights, the clamping of different models of safety valve flanges can be adapted by changing the direction of the jaw 62 facing the central hole 611.

[0063] like Figure 6 As shown, the fixing unit 6 also includes a flange connecting plate 63 mounted on the top rod 53, and the safety valve is mounted on the flange connecting plate 63. When clamping the safety valve to be inspected, the jaw 62 is first moved radially away from the central hole 611 through the first slot 612 or the second slot 613. Then, the pressure at the inlet is reduced to 0.8 MPa by the pressure reducing valve 113 of the air source mechanism 1 to supply air to the purge gun 114, which purges impurities on the clamping table 61. Then, a flange connecting plate 63 that matches the air inlet of the safety valve to be inspected is selected and placed above the top rod 53. The safety valve to be inspected is then placed on the flange connecting plate 63, and the jaw 62 is moved to the outer ring of the safety valve flange. The clamping switch on the control cabinet is pressed, and the hydraulic oil pump 51 starts to work in the forward direction. The hydraulic cylinder 52 drives the top rod 53 and the flange connecting plate 63 to move upward. The top rod 53 moves in the central hole 611, and then slowly lifts the safety valve to be inspected until the safety valve flange reaches the bottom of the jaw protrusion of the jaw 62. When the clamping pressure reaches the set pressure of the data control system, the hydraulic unit 5 stops moving, completing the clamping work of the safety valve to be inspected.

[0064] The automatic safety valve calibration device of this invention takes a safety valve with a pressure channel of 0-1.6 MPa and a preset set pressure of 1 MPa as an example. The specific testing steps are as follows: First, turn on the air source machine 12 and fill the compressed air cylinder 13 with air. Alternatively, an external air source can be connected to the inlet and outlet ports 111. Open the inlet and outlet valves 112 to prepare the air source. Open the inlet valve 14. The pressure is displayed on the pressure gauge 18 before pressure reduction. Adjust the pressure to the required calibration pressure through the pressure reducing valve 15, which is generally 5 times the pressure of the safety valve being tested. The pressure after pressure reduction is displayed on the pressure gauge 19 after pressure reduction. Open the main air source control valve 16, and the air source preparation is complete. Place the safety valve to be tested on the clamping table 61, open the safety valve calibration and control software on the control cabinet, input the relevant information of the safety valve to be calibrated, enter the calibration interface, click the automatic calibration option, and the device starts the automatic calibration process. The data control system automatically opens the channel valve 3 corresponding to the 0-1.6 MPa range and opens the calibration valve 11 to the third open / closed state 103. The air source passes through the calibration valve 11, then through the first channel valve 31, and finally to the corresponding first pressure sensor 4. The first pressure sensor 4 transmits the data back to the data acquisition system, and then to the data analysis system for analysis. The air source also manually reads the pressure values ​​through two mechanical 0-1.6 MPa pressure gauges. When the pressure reaches 0.9 MPa, the data control system controls the calibration valve 11 to the second open / closed state 102 to slowly increase the pressure until the safety valve opens. The data control system records the measured value of the set pressure and performs a pass / fail analysis on the safety valve opening pressure. Simultaneously, it quickly closes the calibration valve 11 to the first open / closed state 101 and opens the pressure relief valve 17 to release the pressure. When the data control system determines that the opening pressure is qualified, it repeats the second and third opening pressure calibrations. If the pressure fails, the data control system prompts that the safety valve test is unqualified and makes adjustments.

[0065] After the three - time opening pressure calibration is qualified, the automatic seal pressure calibration process is carried out. The operator clicks the "Seal Pressure Detection" button on the calibration interface, and the automatic seal pressure calibration process starts. The data control system automatically judges and opens the channel valve 3 with an appropriate range according to the preset seal pressure of the safety valve to be inspected. The data control system controls the calibration valve 11 to open completely for automatic pressure boost, and the pressure boost rate is 0.5 MPa / min - 10 MPa / min to avoid damage to the sealing surface of the safety valve caused by too fast pressure boost. When the real - time pressure reaches the preset seal pressure, the data acquisition system sends a signal to the data control system, and the data control system controls the calibration valve 11 to close, and starts the seal pressure holding test. The pressure holding time can be set to 3 minutes, and the time can be preset and adjusted through the software in the data control system. After the pressure holding time ends, the data acquisition system records the real - time pressure value, that is, the pressure value at the end of pressure holding. The data analysis system calculates the pressure drop during the pressure holding process, that is, the difference between the starting pressure and the ending pressure of pressure holding. If the pressure drop is less than or equal to the preset allowable pressure drop, the seal pressure is judged to be qualified. After the seal pressure calibration is completed, the measured values of the opening pressure three - time setting pressure and the seal pressure are displayed on the calibration interface of the control cabinet, and a calibration report (including safety valve information, calibration data, and qualified judgment result) is generated, which supports PDF format export or printing, and the safety valve calibration certificate can be printed by laser with one key. If the pressure drop is greater than the preset allowable pressure drop, the seal pressure is judged to be unqualified. At the same time, the data control system records the unqualified data and reasons and displays them on the calibration interface.

[0066] After the automatic calibration of the safety valve ends and the pressure of the entire gas circuit is relieved to atmospheric pressure, the operator removes the safety valve, and the data control system controls each module and component to reset and waits for the next calibration.

[0067] In this invention, the control system controls the calibration valve 11 to open and perform staged automatic pressure boost, thereby avoiding pressure overshoot caused by the single - rate pressure boost of the calibration valve 11. When the safety valve to be inspected起跳开启 (it should be "jumps and opens" in English, but this might be a specific term in Chinese patent context, if it has a more accurate English expression, it can be replaced accordingly) and opens, the control system can react in time to close the calibration valve 11, and at the same time, it can avoid damage to the sealing surface of the safety valve caused by too fast pressure boost; by performing multiple opening pressure calibrations, it can avoid accidental errors caused by single - time calibration and improve the calibration accuracy and reliability.

[0068] Although the preferred embodiments in the embodiments of the present invention have been described, those skilled in the art can make additional changes and modifications once they know the basic creative concepts. Therefore, the appended claims are intended to be interpreted to include the preferred embodiments and all changes and modifications falling within the scope of the embodiments of the present invention.

[0069] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An automatic calibration method for a safety valve, characterized in that, This includes a method for enabling stress verification, which comprises the following steps: S1: The control system automatically judges and opens the channel valve (3) with the appropriate range according to the preset set pressure of the safety valve under test. The channel valve (3) is connected to the safety valve under test, the control system and the first pressure sensor (4). S2: The control system controls the verification valve (11) to open and automatically pressurize in stages, wherein the verification valve (11) is connected to the gas source, the safety valve to be tested and the control system; S3: The pressure is increased until the safety valve under test is opened. The first pressure sensor (4) collects the current pressure as the actual value of the set pressure. At the same time, the control system closes the verification valve (11) in time when the safety valve under test is opened. S4: The control system controls the pressure relief of the safety valve under test, and determines whether the opening pressure of the safety valve under test is qualified based on the measured value of the set pressure; S5: If it fails, the verification is terminated and the safety valve opening pressure verification fails; if it passes, the safety valve to be tested is closed and steps S2 to S4 are repeated multiple times to perform multiple opening pressure verifications. If the safety valve to be tested is found to be qualified in all multiple opening pressure verifications, the safety valve opening pressure verification passes; if the safety valve to be tested is found to be unqualified in any of the multiple opening pressure verifications, the verification is terminated and the safety valve opening pressure verification fails.

2. The automatic safety valve calibration method according to claim 1, characterized in that, S2 includes: The control system controls the verification valve (11) to be fully opened for the first stage of pressure increase, and uses the first pressure increase rate to increase the pressure. The control system controls the verification valve (11) to be adjusted to 90% opening for the second stage of pressure increase, and uses a second pressure increase rate, which is lower than the first pressure increase rate.

3. The automatic safety valve calibration method according to claim 2, characterized in that, In the phased automatic pressurization process, the first pressure sensor (4) collects real-time pressure. During the first phase of pressurization, the real-time pressure is lower than 90% of the preset set pressure, and the first pressurization rate is 0.5MPa / min-10MPa / min. When the real-time pressure reaches 90% of the preset set pressure, the control system controls the test valve (11) to adjust to 90% opening for the second stage of pressure increase to continue increasing the pressure until the safety valve to be tested opens, and the second pressure increase rate is less than 0.6MPa / min.

4. The automatic safety valve calibration method according to claim 1, characterized in that, In S3, the first pressure sensor (4) collects the current pressure, and the control system records the current pressure as the measured value of the set pressure. In step S4, determining whether the opening pressure of the safety valve under test is qualified based on the measured value of the set pressure includes: If the measured value of the set pressure is within the acceptable deviation range of the preset set pressure, then the opening pressure of the safety valve under test is qualified; otherwise, the opening pressure of the safety valve under test is unqualified.

5. The automatic safety valve calibration method according to claim 1, characterized in that, In step S5, when the safety valve opening pressure verification fails, the control system records the data during the verification process and records the reason why the opening pressure of the safety valve under test is unqualified based on the measured value of the set pressure and the preset set pressure.

6. The automatic safety valve calibration method according to claim 1, characterized in that, In step S4, the control system controls the pressure relief of the safety valve under test, including: The control system controls the pressure relief valve (17) to open to relieve pressure. When the real-time pressure collected by the first pressure sensor (4) drops to a preset range, the control system controls the pressure relief valve (17) to close. The pressure relief valve (17) is connected to the safety valve to be tested.

7. The automatic calibration method for safety valves according to claim 1, characterized in that, After the safety valve opening pressure test is passed, the automatic safety valve test method further includes a sealing pressure test method, which includes: The control system automatically determines and opens the channel valve (3) with the appropriate range according to the preset sealing pressure of the safety valve under test. The channel valve (3) is connected to the safety valve under test, the control system and the first pressure sensor (4). The control system controls the opening of the verification valve (11) to automatically increase the pressure, and the first pressure sensor (4) collects the real-time pressure. The verification valve (11) is connected to the air source, the safety valve to be tested, and the control system. When the real-time pressure reaches the preset sealing pressure, the control system controls the verification valve (11) to close, and the safety valve to be tested performs sealing and pressure maintenance for a period of time; After the sealing and pressure holding process is completed, the control system calculates the pressure drop during the sealing and pressure holding process based on the current real-time pressure and the initial pressure of the pressure holding process. If the pressure drop is within the preset allowable range, the safety valve sealing pressure test passes; otherwise, the safety valve sealing pressure test fails.

8. The automatic safety valve calibration method according to claim 7, characterized in that, The preset sealing pressure is 90% of the preset set pressure; The control system controls the verification valve (11) to be fully opened for automatic pressure increase, and the pressure increase rate is 0.5MPa / min-10MPa / min.

9. An automatic safety valve calibration device for performing the automatic safety valve calibration method as described in any one of claims 1-8, characterized in that, The system includes a gas source mechanism (1), a clamping mechanism (2), multiple channel valves (3) with different ranges, a first pressure sensor (4), and a control system. The gas source mechanism (1) is used to provide a gas source and includes a calibration valve (11). The clamping mechanism (2) is used to clamp the safety valve to be tested. The gas source mechanism (1), the clamping mechanism (2), and the channel valves (3) are connected through a gas circuit. The gas source mechanism (1), the clamping mechanism (2), the channel valves (3), and the first pressure sensor (4) are communicatively connected to the control system. The control system can control the calibration valve (11) to achieve different opening degree adjustments.

10. The automatic safety valve calibration device according to claim 9, characterized in that, The clamping mechanism (2) includes a clamping platform (61) and multiple claws (62). The clamping platform (61) is provided with a central hole (611) and multiple evenly distributed first slots (612). The claws (62) are slidably disposed on the first slots (612). The clamping platform (61) is also provided with a second slot (613) located between adjacent first slots (612), and the safety valve to be inspected is clamped by the claw (62) at the center hole (611). The jaw (62) is removed from one of the first slots (612) and assembled into the second slot (613). The jaw (62) on the second slot (613) and the jaws (62) on the remaining first slots (612) cooperate to clamp the irregularly shaped safety valve to be inspected. The claw (62) has a first cam (621) and a second cam (622) distributed vertically, and both the first cam (621) and the second cam (622) have slots (623).

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