A water filter cartridge on-line replacement device for a thickness gauge cooling system and a method thereof

Abstract

The application discloses a kind of gauge cooling system water filter element online replacement device and method thereof, belong to the technical field of gauge cooling waterway.This application includes cooling main copper pipe, the cooling main copper pipe is sequentially provided with first flowmeter, main filtration branch, second flowmeter along cooling water flow direction;First handwheel gate valve, detachable water filter element and second handwheel gate valve are respectively arranged on main filtration branch;The first flowmeter and the second flowmeter are also connected with bypass pressure stabilizing branch between them, and third handwheel gate valve is arranged on bypass pressure stabilizing branch.This application has simple structure, low maintenance threshold, greatly simplifies the replacement operation process of gauge cooling system water filter element;Only one person is needed to realize production on-line replacement filter element without stopping machine.On-line replacement operation can guarantee that flowmeter flow is basically stable, and will not interfere with the normal detection work of gauge under production working condition.Effective saving of labor and spare parts investment, realize the dual benefits of operation cost reduction and production efficiency increase.

Description

Technical Field

[0001] This invention relates to the field of thickness gauge cooling water system technology, and more specifically, to an online replacement device and method for the water filter element of a thickness gauge cooling system. Background Technology

[0002] X-ray thickness gauges are commonly used in hot-rolled strip steel production lines for continuous online detection of the finished strip steel thickness. Taking 2250 and 1580 hot-rolling lines as examples, the X-ray thickness gauge generates X-rays by ionizing air using a 100-kilovolt high-voltage system. After the rays penetrate the strip steel, the probe receives the energy of the rays and calculates the real-time thickness data of the strip steel. The high-voltage generator, X-ray tube, and probe inside this type of thickness gauge are all high-power, high-thermal-sensitive components. They generate a huge amount of heat under continuous operation and must be continuously cooled by circulating cooling water at a constant temperature. Once the cooling is interrupted, the high-voltage components will quickly overheat and fail. Therefore, the cooling water circuit is a core supporting system to ensure the long-term stable operation of the thickness gauge.

[0003] Currently, all existing thickness gauges use a single-channel series cooling water circuit. Water filters, flow meters, and other piping components are connected in series inside the cooling service box, allowing cooling water to circulate only along a single path. When impurities accumulate in the cooling water or the filter becomes clogged and dirty, requiring disassembly, cleaning, or replacement, the series piping has no backup flow path, necessitating a complete shutdown of the cooling water circuit. On-site operations require stopping the rolling line production, shutting off the thickness gauge's high-voltage power supply, and then sequentially performing high-voltage reduction, water shut-off, filter removal, reassembly, water reconnection, and high-voltage boost—a single operation taking over an hour. Furthermore, frequent voltage increases and decreases in X-ray high-voltage components generate significant current and voltage surges, continuously damaging the high-voltage lines and the X-ray tube's insulation structure, drastically shortening the lifespan of core components, and significantly increasing equipment spare parts replacement costs.

[0004] Meanwhile, the increasing demands for continuity and stability in strip thickness measurement in current intelligent hot rolling production require X-ray thickness gauges to operate continuously online around the clock. Existing series cooling structures are limited by filter element maintenance; each filter element replacement necessitates a shutdown, consuming valuable production time. Furthermore, the entire maintenance process requires at least two operators, resulting in significant manpower investment and cumbersome procedures. Frequent shutdowns for filter element replacement directly disrupt strip production and cause fluctuations in finished product quality, hindering the achievement of cost reduction and efficiency improvement goals. Current technologies lack supporting pipeline devices for disassembling and cleaning water filters without shutting down the thickness gauge or cutting off high pressure, making them unsuitable for the continuous hot rolling production and maintenance needs. Summary of the Invention

[0005] 1. The technical problem that the invention aims to solve

[0006] To address the shortcomings and deficiencies of existing technologies, this invention provides an online replacement device and method for the water filter element of a thickness gauge cooling system. This invention features a simple structure and low maintenance threshold, significantly simplifying the replacement process for the water filter element in the thickness gauge cooling system. Only a single person is required to perform online filter element replacement without interrupting production. Online replacement ensures the flow rate of the flow meter remains relatively stable and does not interfere with the normal detection operation of the thickness gauge during production. This effectively saves on labor and spare parts input, achieving the dual benefits of reduced maintenance costs and increased production efficiency.

[0007] 2. Technical Solution

[0008] To achieve the above objectives, the technical solution provided by the present invention is as follows:

[0009] The present invention discloses an online replacement device for a water filter element in a thickness gauge cooling system, comprising a main cooling copper pipe, wherein a first flow meter, a main filtration branch, and a second flow meter are sequentially arranged along the cooling water flow direction on the main cooling copper pipe; a first handwheel gate valve, a detachable water filter element, and a second handwheel gate valve are respectively arranged on the main filtration branch; the inlet end of the first handwheel gate valve is connected to the outlet end of the first flow meter, the outlet end of the first handwheel gate valve is connected to the detachable water filter element, an air vent valve is provided on the top of the detachable water filter element, the outlet end of the detachable water filter element is connected to the second handwheel gate valve, and the outlet end of the second handwheel gate valve is connected to the inlet end of the second flow meter;

[0010] A bypass pressure stabilizing branch is connected in series between the first flow meter and the second flow meter. A third handwheel gate valve is provided on the bypass pressure stabilizing branch. The two ends of the third handwheel gate valve are respectively connected to the front end pipeline of the first handwheel gate valve and the rear end pipeline of the second handwheel gate valve.

[0011] Furthermore, the first flow meter and the second flow meter are used to monitor the cooling water flow rate after the main filtration branch and the bypass pressure stabilizing branch merge in real time.

[0012] A method for online replacement of water filter elements in a thickness gauge cooling system, based on an online replacement device for water filter elements in a thickness gauge cooling system, comprises the following steps:

[0013] S1. Bypass pre-conduction: Slowly open the third handwheel gate valve, observe the values ​​of the first and second flow meters throughout the process, control the valve opening to keep the flow of the two combined cooling water lines stable, and let it stand for 30 seconds after the bypass pressure stabilizing branch is fully connected and the flow is stable.

[0014] S2. Isolate the main filter branch: Slowly close the first handwheel gate valve, and after it is completely shut off, slowly close the second handwheel gate valve to completely isolate the branch where the removable water filter element is located.

[0015] S3. Filter replacement: Remove the old filter and replace it with a brand new water purification filter.

[0016] S4. Reverse filling and venting: Open the vent valve on the top of the replaced removable water filter element, and slowly open the second handwheel gate valve. Cooling water flows into the removable water filter element cavity in reverse. Air inside the pipeline is continuously vented by the vent valve until the second handwheel gate valve is fully opened and no air bubbles overflow from the vent valve.

[0017] S5. Resume water flow in the forward direction: Keep the air vent valve open, slowly open the first handwheel gate valve, and observe the readings of the first and second flow meters at any time; let the water flow slowly fill the pipe in the forward direction, and let the air generated in the pipe be slowly discharged through the air vent valve; until the first handwheel gate valve is fully open and no air bubbles overflow from the air vent valve.

[0018] S6. Finishing and Stabilizing Pressure: After observing that there are no air bubbles in the removable water filter element, slowly close the vent valve to ensure that the flow count value remains unchanged, and slowly close the third handwheel gate valve to complete the online replacement of the filter element.

[0019] Furthermore, in S2, during the closing process of the first handwheel gate valve and the second handwheel gate valve, the first flow meter and the second flow meter are monitored in real time, and the two flow meter values ​​are kept constant by slowly closing the valves.

[0020] Furthermore, in S4, the second handwheel gate valve is slowly opened, and the values ​​of the first flow meter and the second flow meter are observed. The two flow meter values ​​are kept constant by opening the valve slowly.

[0021] Furthermore, in S5, the first handwheel gate valve is slowly opened, and the values ​​of the first flow meter and the second flow meter are observed. The two flow meter values ​​are kept constant by opening the valve slowly, allowing the water to slowly fill the pipe in the positive direction.

[0022] Furthermore, the entire operation process is controlled within 5 minutes, and the cooling water flow fluctuation during the switching process is minimal.

[0023] 3. Beneficial effects

[0024] Compared with the prior art, the technical solution provided by this invention has the following advantages:

[0025] This invention significantly simplifies the replacement process of water filter elements in the cooling system of thickness gauges. The operation eliminates the need to wait for production line downtime, removing the cumbersome high-pressure boosting and depressurization procedures involved in X-ray testing. A single person can replace the filter element online without interrupting production. Traditional solutions require coordination of personnel and maintenance time; the modified system allows for independent operation by a single person, significantly improving maintenance convenience. Online replacement ensures stable flow from the flow meter and does not interfere with the normal detection operation of the thickness gauge during production. This device has a simple structure and low maintenance threshold, effectively saving labor and spare parts investment, achieving the dual benefits of reduced maintenance costs and increased production efficiency. Attached Figure Description

[0026] Figure 1 This is an overall system diagram of the present invention.

[0027] In the diagram: 1. Main filtration branch; 2. First flow meter; 3. First handwheel gate valve; 4. Exhaust valve; 5. Removable water filter element; 6. Second handwheel gate valve; 7. Third handwheel gate valve; 8. Second flow meter; 9. Cooling main copper pipe; 10. Bypass pressure stabilizing branch. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0029] Example 1

[0030] from Figure 1 As can be seen, the online replacement device for the water filter element of the thickness measuring instrument cooling system in this embodiment includes a main cooling copper pipe 9. The main cooling copper pipe 9 is sequentially provided with a first flow meter 2, a main filtration branch 1, and a second flow meter 8 along the cooling water flow direction. The main filtration branch 1 is respectively provided with a first handwheel gate valve 3, a detachable water filter element 5, and a second handwheel gate valve 6. The water inlet of the first handwheel gate valve 3 is connected to the water outlet of the first flow meter 2, and the water outlet of the first handwheel gate valve 3 is connected to the detachable water filter element 5. The top of the detachable water filter element 5 is provided with an exhaust valve 4, and the water outlet of the detachable water filter element 5 is connected to the second handwheel gate valve 6. The water outlet of the second handwheel gate valve 6 is connected to the water inlet of the second flow meter 8.

[0031] A bypass pressure stabilizing branch 10 is connected in series between the first flow meter 2 and the second flow meter 8. A third handwheel gate valve 7 is provided on the bypass pressure stabilizing branch 10. The two ends of the third handwheel gate valve 7 are respectively connected to the front end pipeline of the first handwheel gate valve 3 and the rear end pipeline of the second handwheel gate valve 6.

[0032] The first flow meter 2 and the second flow meter 8 are used to monitor the cooling water flow rate after the main filtration branch 1 and the bypass pressure stabilizing branch 10 merge in real time.

[0033] Example 2

[0034] from Figure 1 As can be seen, the online replacement method for the water filter element of the thickness gauge cooling system in this embodiment is based on an online replacement device for the water filter element of the thickness gauge cooling system. When the filter element is found to be dirty during on-site inspection and needs to be replaced, only one person needs to operate it online. The steps are as follows:

[0035] S1. Bypass pre-conduction: Slowly open the third handwheel gate valve 7, observe the values ​​of the first flow meter 2 and the second flow meter 8 throughout the process, control the valve opening to keep the flow of the two combined cooling water lines stable, and let it stand for 30 seconds after the bypass pressure stabilizing branch 10 is fully connected and the flow is stable.

[0036] S2. Isolate the main filter branch 1: Slowly close the first handwheel gate valve 3, and after it is completely shut off, slowly close the second handwheel gate valve 6 to completely isolate the branch where the removable water filter element 5 is located.

[0037] In S2, during the closing of the first handwheel gate valve 3 and the second handwheel gate valve 6, the first flow meter 2 and the second flow meter 8 are monitored in real time, and the two flow meter values ​​are kept constant by slowly closing the valves.

[0038] S3. Filter replacement: Remove the old filter and replace it with a brand new water purification filter.

[0039] S4. Reverse filling and venting: Open the venting valve 4 on the top of the replaced removable water filter element 5, and slowly open the second handwheel gate valve 6. Cooling water flows into the cavity of the removable water filter element 5 in reverse. During this period, the air generated in the pipe due to the replacement of the filter element is continuously discharged by the venting valve 4 until the second handwheel gate valve 6 is fully opened and no air bubbles overflow from the venting valve 4.

[0040] In S4, slowly open the second handwheel gate valve 6 and observe the values ​​of the first flow meter 2 and the second flow meter 8. Ensure that the two flow meter values ​​remain unchanged by slowly opening the valve.

[0041] S5. Resume water flow in the forward direction: Keep the air vent valve 4 open, slowly open the first handwheel gate valve 3, and observe the values ​​of the first flow meter 2 and the second flow meter 8 at any time; let the water flow slowly fill the pipe in the forward direction, and the air generated in the pipe will be slowly discharged through the air vent valve 4; until the first handwheel gate valve 3 is fully open and no air bubbles overflow from the air vent valve 4.

[0042] Slowly open the first handwheel gate valve 3 in S5, observe the values ​​of the first flow meter 2 and the second flow meter 8, and ensure that the two flow meter values ​​remain unchanged by slowly opening the valve; allow the water to slowly fill the pipe in the positive direction.

[0043] S6. Finishing and stabilizing pressure: After observing that there are no air bubbles in the removable water filter element 5, slowly close the exhaust valve 4 to ensure that the flow count value remains unchanged, and slowly close the third handwheel gate valve 7 to complete the online replacement of the filter element.

[0044] The entire operation process is controlled within 5 minutes, and the cooling water flow fluctuation is minimal during the switching process. This operation is intuitive and clear, which can facilitate the maintenance of thickness gauges.

[0045] Comparative Example 1

[0046] In existing technology, the control cabinet of the thickness gauge cooling system adopts a series layout, with the flow meter and water filter element assembled in series. Once the filter element becomes clogged or dirty and needs replacement, the entire operation process is complex, with the following specific steps: First, the operation must be scheduled during production line shutdown or regular maintenance periods to ensure the thickness gauge is not measuring; Second, disconnect the network communication between the thickness gauge and the field equipment at the main control cabinet, and gradually reduce the X-ray high voltage from 195KV, 10mA to 100KV, 5mA, a reduction that takes approximately 20 minutes, after which the X-ray high voltage is shut off; Third, disconnect the power supply to the cooler and drain the water pressure in the pipeline; Fourth, remove and replace the cooling system water filter element; Fifth, restore the cooler power supply, adjust the cooling water flow, and gradually increase the pressure again, raising the high voltage parameters from 100KV, 5mA back to 195KV, 10mA, a pressure increase process that takes approximately 30 minutes. The entire replacement process involves many steps and is time-consuming; even with two skilled operators working together, the overall operation time is still close to one hour. The high-voltage boosting and depressurization process for X-rays consumes the majority of the working time, resulting in low maintenance efficiency.

[0047] In comparison, this invention is tailored to on-site working conditions and enables rapid replacement of the water filter element in the thickness gauge cooling system. This solution not only meets the requirements for rapid online disassembly and replacement under production conditions but also significantly reduces wear and damage to equipment caused by frequent high-pressure fluctuations, effectively saving on spare parts costs.

[0048] Based on the device of this invention, we can replace the water filter cartridge without reducing high pressure or interrupting power and water supply. When the filter cartridge needs to be replaced, only one person is needed to operate it online. First, open handwheel gate valve No. 3 to ensure smooth water flow in the pipeline; second, close handwheel gate valves No. 1 and No. 2, and then you can directly replace the filter cartridge; finally, after replacing the filter cartridge, open handwheel gate valves No. 1 and No. 2, and close handwheel gate valve No. 3. The online filter cartridge replacement operation is completed.

[0049] After the application of this device, the replacement process of the water filter element in the thickness gauge cooling system has been greatly simplified. The operation no longer requires waiting for production line downtime, eliminating the need for a complete set of cumbersome X-ray high-pressure boosting and depressurization operations. A single person can replace the filter element online without stopping production. Traditional solutions require coordination of multiple personnel and maintenance time; the modified device allows a single person to complete the operation independently, significantly improving maintenance convenience. Online replacement ensures the flow rate of the flow meter remains relatively stable and does not interfere with the normal detection operation of the thickness gauge under production conditions. This device has a simple structure and low maintenance threshold, effectively saving labor and spare parts investment, achieving the dual benefits of reduced maintenance costs and increased production efficiency.

[0050] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. An online replacement device for the water filter element of a thickness gauge cooling system, comprising a main cooling copper pipe (9), characterized in that: The cooling main copper pipe (9) is provided with a first flow meter (2), a main filter branch (1) and a second flow meter (8) in sequence along the cooling water flow direction; a first handwheel gate valve (3), a detachable water filter element (5) and a second handwheel gate valve (6) are respectively provided on the main filter branch (1); the inlet end of the first handwheel gate valve (3) is connected to the outlet end of the first flow meter (2), the outlet end of the first handwheel gate valve (3) is connected to the detachable water filter element (5), the top of the detachable water filter element (5) is provided with an exhaust valve (4), the outlet end of the detachable water filter element (5) is connected to the second handwheel gate valve (6), and the outlet end of the second handwheel gate valve (6) is connected to the inlet end of the second flow meter (8); A bypass pressure stabilizing branch (10) is connected in series between the first flow meter (2) and the second flow meter (8). A third handwheel gate valve (7) is provided on the bypass pressure stabilizing branch (10). The two ends of the third handwheel gate valve (7) are respectively connected to the front end pipeline of the first handwheel gate valve (3) and the rear end pipeline of the second handwheel gate valve (6).

2. The online replacement device for the water filter element of a thickness gauge cooling system according to claim 1, characterized in that: The first flow meter (2) and the second flow meter (8) are used to monitor the cooling water flow rate after the main filtration branch (1) and the bypass pressure stabilizing branch (10) merge in real time.

3. A method for online replacement of water filter element in a thickness gauge cooling system, based on the online replacement device for water filter element in a thickness gauge cooling system as described in claim 2, characterized in that: The steps are as follows: S1. Bypass pre-conduction: Slowly open the third handwheel gate valve (7), observe the values ​​of the first flow meter (2) and the second flow meter (8) throughout the process, control the valve opening to keep the flow of the two combined cooling water lines stable, and let it stand for 30 seconds after the bypass pressure stabilizing branch (10) is fully connected and the flow is stable. S2. Isolate the main filter branch (1): Slowly close the first handwheel gate valve (3), and after it is completely shut off, slowly close the second handwheel gate valve (6) to completely isolate the branch where the detachable water filter element (5) is located. S3. Filter replacement: Remove the old filter and replace it with a brand new water purification filter. S4, Reverse filling and venting: Open the vent valve (4) on the top of the replaced removable water filter element (5), slowly open the second handwheel gate valve (6), and the cooling water flows into the cavity of the removable water filter element (5) in reverse. The air inside the pipeline is continuously discharged by the vent valve (4) until the second handwheel gate valve (6) is fully opened and no air bubbles overflow from the vent valve (4). S5. Resume water flow in the forward direction: Keep the air vent valve (4) open, slowly open the first handwheel gate valve (3), and observe the values ​​of the first flow meter (2) and the second flow meter (8) at any time; let the water flow slowly fill the pipe in the forward direction, and the air generated in the pipe will be slowly discharged through the air vent valve (4); until the first handwheel gate valve (3) is fully opened and no air bubbles overflow from the air vent valve (4); S6. Finishing and stabilizing pressure: After observing that there are no air bubbles in the removable water filter element (5), slowly close the exhaust valve (4) to ensure that the flow count value remains unchanged, and slowly close the third handwheel gate valve (7) to complete the online replacement of the filter element.

4. The method for online replacement of water filter element in a thickness gauge cooling system according to claim 3, characterized in that: In S2, during the closing process of the first handwheel gate valve (3) and the second handwheel gate valve (6), the first flow meter (2) and the second flow meter (8) are monitored in real time, and the two flow meter values ​​are kept constant by slowly closing the valves.

5. The method for online replacement of water filter element in a thickness gauge cooling system according to claim 3, characterized in that: In S4, the second handwheel gate valve (6) is slowly opened, and the values ​​of the first flow meter (2) and the second flow meter (8) are observed. The two flow meter values ​​are kept constant by opening the valve slowly.

6. The method for online replacement of water filter element in a thickness gauge cooling system according to claim 3, characterized in that: In S5, the first handwheel gate valve (3) is slowly opened, and the values ​​of the first flow meter (2) and the second flow meter (8) are observed. The two flow meter values ​​are kept constant by slowly opening the valve. The water flow slowly fills the pipe in the positive direction.

7. The method for online replacement of water filter element in a thickness gauge cooling system according to claim 3, characterized in that: The entire operation process is controlled within 5 minutes, and the cooling water flow fluctuation is minimal during the switching process.

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