A valve leakage plugging device and plugging method

Abstract

The application relates to a valve leakage plugging device and a plugging method, and relates to the technical field of valve leakage plugging.The application has the beneficial effects that the application realizes quick, safe and permanent plugging of a valve leakage point under the condition that a pipeline system does not stop conveying and a medium is continuously under pressure.A pressure relief and drainage assembly arranged at the bottom of a lower cover body can effectively discharge the leaked medium in a sealed chamber during welding, guarantees that the welding area is dry, greatly reduces the difficulty and safety risk of pressure welding operation, and ensures the welding quality; a sealing cover shell formed by integral welding of an upper cover body and the lower cover body completely encapsulates the leaked valve and integrates the valve into the pipeline system, permanent mechanical sealing is realized, and the plugging life is equivalent to that of the pipeline; a standby valve of the same specification is installed at the rear end of the leaked valve, the pipeline opening and closing control function is restored at the same time when the plugging is completed, and the problem that the pipeline section loses control after being plugged is solved.

Description

Technical Field

[0001] This invention relates to the field of valve leakage sealing technology, specifically to a valve leakage sealing device and sealing method. Background Technology

[0002] In industrial pipeline networks operating in continuous production processes, such as smelting water supply, petrochemicals, and municipal heating, valves are critical fluid control devices. Due to long-term operation, media corrosion, fluctuations in operating conditions, and aging of seals, valves (especially at valve body, stem seals, or flange connections) frequently leak. Once a valve leaks, it not only wastes media and pollutes the environment, but in severe cases, it can also affect the safe operation of the entire system.

[0003] Traditional maintenance methods involve shutting down the relevant pipeline section, depressurizing and purging the pipeline, and then removing and replacing the leaking valve. However, for critical valves in main pipelines or ring networks, shutdown often means large-scale production stoppages, resulting in significant economic losses and potentially impacting safe production. Therefore, how to quickly, safely, and reliably seal leaking valves without interrupting supply or production has become a pressing technical challenge in the field of industrial pipeline maintenance.

[0004] Currently, the industry has developed various live leak sealing technologies, including injection-type sealing, clamp-type sealing, and binding-type sealing. However, most of these existing technologies are designed for small-area point leaks or linear leaks such as pinholes and cracks in the pipeline itself. They are ineffective in handling severe leaks such as leaks caused by overall valve body cracks, large-area failure of flange sealing surfaces, or severe damage to valve stem packing. Especially when it is necessary to retain the valve's original position (such as when it is used as a maintenance shut-off valve in a pipeline) without disassembling the valve, the capabilities of existing technologies are even more limited.

[0005] Therefore, there is an urgent need for a device and method that can provide a complete, permanent, safe and reliable uninterrupted sealing solution for leaking valves, in order to solve the problems existing in the prior art. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings and defects of the prior art by providing a valve leakage sealing device and sealing method.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a valve leakage sealing device and sealing method, comprising a water supply main pipe, a pipe on one side of the water supply main pipe, a leakage valve installed on the pipe, an upper cover and a lower cover on the outside of the leakage valve, both the upper cover and the lower cover being semi-enclosed shells, and the lower cover and the upper cover being horizontally connected and welded to form a sealed chamber, the sealed chamber being used to completely enclose the leakage valve and the pipes at both ends, a drainage hole being opened at the bottom of the lower cover, and a pressure relief drainage component being connected to the drainage hole, the pressure relief drainage component being used to discharge the medium in the sealed chamber during the sealing operation.

[0008] Furthermore, the pressure relief and drainage assembly includes a drainage short tube and a drainage control valve installed at the free end of the drainage short tube, with one end of the drainage short tube fixedly connected to the drainage hole.

[0009] Furthermore, the drainage short tube and the drainage control valve are detachably connected by threads.

[0010] Furthermore, the top edge of the lower cover and the bottom edge of the upper cover are provided with matching welding bevels.

[0011] Furthermore, the inner wall contours of both the lower and upper covers are adapted to the outer contours of the leakage valve and pipeline.

[0012] Furthermore, it also includes a backup valve of the same specifications as the leaking valve, which is used to install on the pipeline downstream of the leaking valve to restore the pipeline's opening and closing control function after sealing.

[0013] A method for sealing valve leakage includes the following steps: confirming that the leaking valve is in a closed state; installing a spare valve on the pipeline downstream of the leaking valve, and then opening the leaking valve; treating and wrapping the leaking point of the leaking valve to prevent jet-like leakage that would affect welding operations; placing a lower cover under the leaking valve to cover the lower half of the valve and the pipeline, opening and keeping the drain control valve in the open state, and then sealing and welding the lower cover to the pipelines at both ends of the valve, during which the leaked medium is discharged through the pressure relief and drain assembly; fastening an upper cover onto the lower cover, ensuring a tight fit between the mating edges, and then welding the upper cover and lower cover together along the mating seam to form a complete sealing shell, during which the leaked medium is discharged through the pressure relief and drain assembly; after the sealing shell is completely welded and there is no leakage, closing the drain control valve of the pressure relief and drain assembly.

[0014] Furthermore, it also includes a step of performing anti-corrosion treatment on the outer surface of the sealing cover.

[0015] After adopting the above technical solution, the beneficial effects of the present invention include at least the following points: 1. The entire sealing process does not require system shutdown or depressurization. All operations can be completed while the medium is under pressure, maximizing the continuity of production and avoiding huge economic losses caused by production stoppages.

[0016] 2. By using the pressure relief and drainage components, drainage holes, drainage short pipes, and drainage control valves installed at the bottom of the lower cover, the leaked medium in the sealed chamber can be effectively discharged during the welding process, keeping the welding area dry. This greatly reduces the difficulty and safety risks of live welding, while ensuring welding quality and enabling the sealing body to reliably withstand the pipeline working pressure.

[0017] 3. The sealing shell formed by welding the upper and lower covers together completely encapsulates the leakage valve and integrates it into the pipeline system, achieving a permanent mechanical seal with a sealing life equal to that of the pipeline, eliminating the need for subsequent repeated maintenance.

[0018] 4. The upper and lower covers adopt a semi-enclosed shell structure, which can be flexibly manufactured and adapted according to different valve sizes. The method and steps are clear and suitable for rapid on-site implementation, especially suitable for maintenance conditions where space is limited and valves cannot be disassembled.

[0019] 5. By installing a backup valve of the same specification at the downstream end of the leaking valve, the restoration of pipeline regulation and shut-off functions is ensured while the sealing is completed, solving the problem of loss of control of the pipeline section after sealing and realizing an integrated solution of sealing and functional replacement. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the 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.

[0021] Figure 1 This is a schematic diagram of the structure of the present invention.

[0022] Figure 2 This is a schematic diagram of the invention from another angle.

[0023] Figure 3 This is a schematic diagram of the structure of the lower cover and the drainage hole in this invention.

[0024] Explanation of reference numerals in the attached diagram: 1. Spare valve; 2. Upper cover; 3. Leakage valve; 4. Main water supply pipe; 5. Lower cover; 6. Drainage short pipe; 7. Drainage control valve; 8. Drainage hole. Detailed Implementation

[0025] 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 a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] In the description of this invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inner", "outer", "horizontal", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and 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 this invention.

[0027] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature.

[0028] In the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," "fixing," "welding," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Example 1

[0029] like Figure 1 and Figure 2 As shown, the valve leakage sealing device provided by this invention mainly includes an upper cover 2 and a lower cover 5. Both the upper cover 2 and the lower cover 5 are semi-enclosed shell structures, formed by rolling or pressing steel plates. The upper cover 2 and the lower cover 5 are welded together to form a sealed whole, creating a sealing shell used to completely enclose the leaking valve 3 and the pipes at both ends. The internal shape of the upper cover 2 and the lower cover 5 needs to be designed according to the external dimensions of the target valve, such as the DN50 flanged ball valve in this embodiment, and the pipes at both ends. The inner wall contour is adapted to the external contour of the valve and pipes, and an appropriate installation gap is reserved for rapid on-site installation.

[0030] The top edge of the lower cover 5 is provided with a welding bevel, and the bottom edge of the upper cover 2 is provided with a matching welding bevel to ensure good welding quality and sealing performance when the upper and lower covers are welded together.

[0031] A drainage hole 8 is provided at the center of the bottom of the lower cover 5. The pressure relief and drainage assembly consists of a short drainage pipe 6 and a small-diameter drainage control valve 7, which is preferably a DN15 or DN20 ball valve. One end of the short drainage pipe 6 is welded to the drainage hole 8, and the other end is threaded, which allows for detachable connection to the drainage control valve 7. During the sealing welding operation, the drainage control valve 7 is in the open state, and the leaked medium is discharged to a safe area through the drainage hole 8, the short drainage pipe 6, and the drainage control valve 7, ensuring that no medium accumulates in the welding area.

[0032] like Figure 3 As shown, the drainage hole 8 is located at the bottom center of the lower cover 5, and the drainage short tube 6 is vertically connected to the drainage hole 8. The lower end of the drainage short tube 6 is provided with threaded teeth, and the drainage control valve 7 is detachably connected to the drainage short tube 6 through the threaded teeth.

[0033] In addition, the device also includes a spare valve 1 of the same model and specifications as the leakage valve 3, which is installed on the pipeline downstream of the leakage valve 3 to restore the opening and closing control function of the pipeline section after the sealing operation is completed. Example 2

[0034] This embodiment uses the example of sealing a leak in a DN50 flange-connected ball valve to illustrate in detail the valve leak sealing method of the present invention.

[0035] like Figures 1 to 3 As shown, a pipe is provided on one side of the main water supply pipe 4, and a leakage valve 3 is installed on the pipe. The sealing method of the present invention includes the following steps: Step S1: Preliminary preparation and confirmation.

[0036] Confirm that leak valve 3 is closed. Although there may be internal leakage, closing the valve will significantly reduce the leakage and create better working conditions for subsequent operations. Simultaneously, assess on-site safety conditions and prepare welding equipment, fire-fighting equipment, and personal protective equipment.

[0037] Step S2: Install the backup control valve.

[0038] At an appropriate downstream location after leakage valve 3, cut a section of pipe and install a new ball valve of the same specifications as leakage valve 3 as backup valve 1. After backup valve 1 is installed, open leakage valve 3. This step ensures that the pipeline still has normal shut-off and control functions after the original valve is plugged.

[0039] Step S3: Leakage Pre-processing.

[0040] Clean and simply wrap the leak point of valve 3, using sealing tape or sealant to prevent the leaking medium from spraying or splashing, thus avoiding interference with subsequent welding operations. This step can be performed using methods such as wrapping sealing tape, applying sealant, or installing temporary clamps, depending on the actual condition of the leak, to prevent spraying leakage.

[0041] Step S4: Install and weld the lower cover.

[0042] Clean the oil, rust, and original anti-corrosion layer from the surface of the leak valve 3 and surrounding pipelines. Insert the prefabricated lower cover 5 from below, enclosing the lower half of the leak valve 3 and the bottom pipeline. Adjust the position of the lower cover 5 so that both ends of the lower cover 5 fit tightly against the pipeline. Open the drainage control valve 7 of the pressure relief and drainage assembly and keep it open. Then, weld both ends of the lower cover 5 to the pipeline at a full circumference to ensure a seal. Throughout the welding process, the medium leaking from the leak valve 3 continuously drains through the drainage hole 8 at the bottom of the lower cover 5, the drainage short pipe 6, and the drainage control valve 7, preventing the medium from accumulating inside the lower cover 5, thus ensuring welding quality and operational safety.

[0043] Step S5: Install and weld the cover.

[0044] The upper cover 2 is fastened onto the lower cover 5, ensuring a tight fit between their mating edges and aligning the weld bevels. Then, the upper cover 2 and lower cover 5 are welded together along the butt joint to form a complete sealed enclosure. Throughout the welding process, any gas present in the sealed chamber and any small amounts of leaked media are safely discharged through the open drainage control valve 7, creating a favorable environment for the welding operation and ensuring the quality of the weld.

[0045] Step S6: Sealing completed and finalized.

[0046] After all welds are completed and have cooled sufficiently, slowly close the drainage control valve 7 of the pressure relief and drainage assembly. Check all welds on the sealing cover for any signs of leakage. Once it is confirmed that there are no leaks, clean the outer surface of the sealing cover and apply anti-corrosion paint for corrosion protection, completing the entire sealing operation.

[0047] At this point, the leakage valve 3 is completely sealed within a robust sealing housing, the leakage is completely eliminated, and the flow and control functions of the pipeline are maintained through the backup valve 1. Example 3

[0048] For leakage valves of different specifications and types, the device of the present invention can be customized according to the actual size and shape of the valve. Specifically, when designing the upper cover 2 and the lower cover 5, the leakage valve 3 and the pipelines at both ends can be surveyed on-site first to determine the outline dimensions and spatial relationship of the valve and pipelines. Then, a cover mold adapted to the survey data is made, followed by the cutting, rolling, and welding of steel plates. For flange connections or valve stem protrusions, corresponding avoidance bumps can be provided on the cover. The diameter of the drainage short pipe 6 in the pressure relief and drainage assembly can be selected according to the flow rate of the leakage medium, generally preferably DN15~DN25, to ensure timely discharge of the leakage medium.

[0049] The above is only used to illustrate the technical solution of the present invention and is not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of the present invention, as long as they do not depart from the spirit and scope of the technical solution of the present invention, should be covered within the scope of the claims of the present invention.

Claims

1. A valve leakage sealing device, comprising a main water supply pipe (4), wherein a pipe is provided on one side of the main water supply pipe (4), and a leakage valve (3) is installed on the pipe, characterized in that: The leakage valve (3) is provided with an upper cover (2) and a lower cover (5) on its outer side. The upper cover (2) and the lower cover (5) are both semi-enclosed shells. The lower cover (5) and the upper cover (2) are connected horizontally and welded to form a sealed chamber. The sealed chamber is used to completely enclose the leakage valve (3) and the pipes at both ends. The bottom of the lower cover (5) is provided with a drainage hole (8). A pressure relief drainage assembly is connected to the drainage hole (8). The pressure relief drainage assembly is used to discharge the medium in the sealed chamber during the sealing operation.

2. The valve leakage sealing device according to claim 1, characterized in that: The pressure relief and drainage assembly includes a drainage short tube (6) and a drainage control valve (7) installed at the free end of the drainage short tube (6). One end of the drainage short tube (6) is fixedly connected to the drainage hole (8).

3. The valve leakage sealing device according to claim 1, characterized in that: The drainage short tube (6) and the drainage control valve (7) are detachably connected by threads.

4. The valve leakage sealing device according to claim 1, characterized in that: The top edge of the lower cover (5) and the bottom edge of the upper cover (2) are provided with matching welding bevels.

5. A valve leakage sealing device according to claim 1, characterized in that: The inner wall contours of the lower cover (5) and the upper cover (2) are adapted to the outer contours of the leakage valve (3) and the pipeline.

6. A valve leakage sealing device according to claim 1, characterized in that: It also includes a spare valve (1) of the same specifications as the leak valve (3), the spare valve (1) being installed on the pipeline downstream of the leak valve (3) to restore the pipeline’s opening and closing control function after sealing.

7. A valve leakage sealing method, implemented using the valve leakage sealing device as described in any one of claims 1 to 6, characterized in that, Includes the following steps: S1: Confirm that the leakage valve (3) is closed; S2: Install a spare valve (1) on the pipeline behind the leakage valve (3), and then open the leakage valve (3); S3: Address the leak point of the leaking valve (3) to prevent it from producing jet-like leakage and thus affecting the welding operation; S4: Place the lower cover (5) below the leakage valve (3) so that it covers the lower half of the valve and the pipeline. Open and keep the drainage control valve (7) in the open state. Then, seal and weld the lower cover (5) to the pipelines at both ends of the valve. During this process, the leaked medium is discharged through the pressure relief drainage assembly. S5: Fasten the upper cover (2) onto the lower cover (5) so that the mating edges of the two fit tightly together. Then weld the upper cover (2) and the lower cover (5) together along the mating seam to form a complete sealing cover. During this process, the leaked medium is discharged through the pressure relief and drainage assembly. S6: After the sealing cover is welded as a whole and there is no leakage, close the drainage control valve (7) of the pressure relief drainage assembly.

8. A valve leakage sealing method according to claim 7, characterized in that: After step S6, the method further includes a step of performing anti-corrosion treatment on the outer surface of the sealing cover.

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