Cooler pressure test system
By designing a cooler pressure test system and using automatic recording pressure gauges and flow meters to perform pressure tests and leak detection, the problem of difficult monitoring of cooler water pipe damage has been solved, the pressure testing efficiency and leak detection quality have been improved, and the high-quality online operation of metallurgical furnaces has been ensured.
Patent Information
- Application Number
- CN202422103313.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-29
- Publication Date
- 2025-10-10
- Estimated Expiration
- 2034-08-29
AI Technical Summary
Existing coolers are difficult to monitor after water pipe damage, resulting in poor cooling effects and difficulty in replacement, which affects the production quality of metallurgical furnaces.
A cooler pressure test system was designed, including a water supply unit, a cooler connection unit, a water outlet unit, a water return unit and a detection unit. An automatic recording pressure gauge and a flow meter were used to detect pressure and flow, and pressure and leak detection were performed according to pressure and conditions.
It improves the pressure-testing efficiency and leak detection quality, eliminates quality problems such as casting and welding, ensures the high-quality operation of metallurgical furnaces, and reduces water consumption.
Smart Images
Figure CN223426182U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of cooling in the metallurgical industry, and in particular relates to a cooler pressure testing system. Background Art
[0002] Industrial kilns are essential for most production processes in both iron and steel metallurgy and nonferrous metallurgy. These furnaces are primarily used for thermal processing of various materials and workpieces during metallurgical production. Energy consumption in the metallurgical industry is largely determined by the energy consumption of various furnaces. Modern metallurgical furnaces can be categorized by heat source: fuel-fired furnaces, electric furnaces, and self-heating furnaces. Cooling systems can be divided into air-cooled and water-cooled, depending on the cooling medium. Water-cooled systems are widely used due to their uniform cooling performance and excellent cooling efficiency. Soft water offers even better cooling effects.
[0003] A cooling stave is a type of cooler commonly used in metallurgical furnaces. Depending on the material used, it can be categorized as cast iron, copper, steel, and steel-copper composite. The main function of a cooling stave is to smoothly conduct heat away from the furnace through surface cooling, preventing high-temperature heat from directly reaching the furnace shell. This effect is achieved by installing the cooling stave between the brick lining and the furnace shell. Modern blast furnaces employing a full-stave cooling structure have cooling staves or water-cooled staves installed throughout the furnace shell from the furnace bottom to the throat, forming a fully cooled furnace structure. Heat transferred from the blast furnace is transferred to the environment via cooling water through heat exchange with the cooling staves.
[0004] However, cooling staves also have their technical drawbacks, with two of the most prominent issues being the difficulty of repair and replacement, requiring the blast furnace to be shut down and the charge level to be lowered; and the difficulty of detecting damaged water pipes. These issues necessitate pressure testing and leak detection before production to prevent quality issues with casting, welding, and piping, which could seriously impact the effectiveness of online applications. However, this process requires rapid detection of the cooling stave's compliance at the required water pressure for coolers of varying specifications, as well as leaks, their location, and their remediability. These are pressing challenges facing those skilled in the art. Utility Model Content
[0005] Aiming at the problem that it is difficult to find a damaged water pipe, which leads to poor cooling effect of the cooler, the utility model provides a cooler pressure test system.
[0006] A cooler pressure test system comprises a water supply unit, a cooler connection unit, a water outlet unit and a water return unit connected in sequence, and also comprises a detection unit;
[0007] The water supply unit includes a water inlet pipe and a first ball valve; the cooler connection unit includes a metal hose, a quick connector, the cooler to be tested and its water inlet and water outlet; the water outlet unit includes a water outlet pipe and a second ball valve; the return water unit includes a water tank, a return water pipe and a gate valve; the detection unit includes an automatic recording pressure gauge and a flow meter; the water inlet pipe is provided with an automatic recording pressure gauge, and the flow meter includes a first flow meter provided on the water inlet pipe and a second flow meter provided on the water outlet pipe.
[0008] Furthermore, the water pressure range of the water inlet pipe of the water supply unit is maintained at 0.40-0.80 MPa.
[0009] Furthermore, the pressure resistance of the metal hose and the quick connector is not less than 0.80 MPa.
[0010] The beneficial effect of this utility model is that before the cooler is put into production, pressure testing and leak detection must be carried out, eliminating quality problems such as casting, welding and piping that seriously affect the online application effect. This utility model improves pressure testing efficiency and leak detection quality, providing a solid guarantee for the industrial production of metallurgical furnaces. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 It is a structural diagram of the utility model;
[0012] In the figure: 1-water inlet pipe; 2-automatic recording pressure gauge; 3-first flow meter; 4-first ball valve; 5-metal hose; 6-quick connector; 7-cooler water inlet; 8-cooler; 9-cooling water channel; 10-cooler water outlet; 11-second flow meter; 12-second ball valve; 13-water outlet pipe; 14-water outlet head; 15-water tank; 16-water tank outlet pipe; 17-gate valve; 18-return pipe. DETAILED DESCRIPTION
[0013] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:
[0014] like Figure 1 As shown, a cooler pressure test system includes a water inlet pipe 1, an automatic recording pressure gauge 2, a first flow meter 3, and a first ball valve 4 connected in sequence. The water is connected to the water inlet 7 of the cooler 8 by a quick connector 6 through a metal hose 5. After entering the cooler 8, the water flows out from the cooler outlet 10 through the cooling water channel 9, passes through the second flow meter 11 and the second ball valve 12, and flows out from the outlet pipe 13, forming an outlet water head 14.
[0015] When the water inlet pressure reaches 0.40 MPa or higher, water enters the cooler 8 and flows out through the cooling water channel 9. A leak in the channel can be determined by observing one of the following two phenomena: First, the reading on the second flowmeter 11 is less than that on the first flowmeter 3, indicating that water flowing through the pipeline is leaking from the leak. Second, by controlling the opening of the second ball valve 12 from fully open to 3 / 4, then 1 / 2, and finally 1 / 4, observing the water flowing out of the outlet pipe 13. A white line appears at the outlet head 14, indicating that air has infiltrated the water flow from the leak. This is due to the formation of a thin white line of water containing bubbles during the water flow control process.
[0016] The water flowing out of the cooler flows into the water tank 15 and passes through the water tank outlet pipe 16 and the opened gate valve 17, and enters the water recycling system through the return pipe 18.
[0017] Generally, the water pressure is divided into 0.40MPa. Water below 0.40MPa is normal pressure water, which is mainly used for pressure testing and leak detection of coolers with lower working pressure; 0.40-0.80MPa is high pressure water, which is mainly used for pressure testing and leak detection of coolers with higher working pressure, such as blast furnace cooling walls, slag vents, etc.
[0018] The utility model is based on the direct water filling leak detection of the cooler, and performs system pressure testing and leak detection according to pressure and conditions, so as to complete the pressure testing and leak detection with high efficiency and high quality, and prevent the occurrence of quality problems such as casting, welding and piping that seriously affect the online application effect. The return water is recycled to reduce water consumption, which provides a strong guarantee for the high-quality online use of the cooler in metallurgical furnaces.
Claims
1. A cooler pressure test system, characterized in that: It includes a water supply unit, a cooler connection unit, a water outlet unit and a water return unit connected in sequence, and also includes a detection unit; The water supply unit includes a water inlet pipe and a first ball valve; the cooler connection unit includes a metal hose, a quick connector, the cooler to be tested and its water inlet and water outlet; the water outlet unit includes a water outlet pipe and a second ball valve; the return water unit includes a water tank, a return water pipe and a gate valve; the detection unit includes an automatic recording pressure gauge and a flow meter; the water inlet pipe is provided with an automatic recording pressure gauge, and the flow meter includes a first flow meter provided on the water inlet pipe and a second flow meter provided on the water outlet pipe.
2. A cooler pressure test system according to claim 1, characterized in that: The water pressure range of the water supply unit inlet pipe is maintained at 0.40-0.80MPa.
3. A cooler pressure test system according to claim 1, characterized in that: The pressure resistance of the metal hose and quick connector is not less than 0.80 MPa.