Online valve replacement tool

Abstract

The utility model belongs to the technical field of valve overhaul and maintenance, and particularly relates to an on-line valve replacement tool which comprises an octagonal pad displacement tool which is installed on an octagonal pad of a valve flange opening, abuts against the octagonal pad through a jackscrew and is used for moving the octagonal pad. Adjusting the gaps between the octagonal pad and the valve flange opening and the pipeline flange opening; the split sealing plate is used for ejecting out the octagonal pad and is assembled in a gap between the valve flange opening and the pipeline flange opening, and a split blocking sealing shaft is arranged on the split sealing plate and is used for blocking an inner cavity of the pipeline flange opening; and the valve plugging mounting frame is fixed on the pipeline, is connected with the split type plugging sealing shaft through a central through buckle screw rod, and is used for supporting the pipeline and the split type plugging sealing shaft when the valve is dismounted. The utility model solves the problem that the flange surface is difficult to clean when the valve is replaced, reduces the loss of the catalyst, and fundamentally solves the leakage problem caused by the factors such as larger leakage of the pipeline catalyst and incapability of blocking.

Description

Technical Field

[0001] This utility model belongs to the field of valve inspection and maintenance technology, specifically relating to an online valve replacement tool and its replacement method. Background Technology

[0002] Due to long-term operation of the reactor equipment, the reactor pipelines have been locally thinned by the internal catalyst, the valve plates may not open or close properly, and the valve packing may leak. Therefore, it is necessary to dismantle, repair and replace the equipment. There are currently two construction plans.

[0003] (1) Shut down the local pipeline system, drain the catalyst from the bottom of the reactor, and then replace the pipeline valves. This solution can fundamentally solve the problem, but the maintenance cycle is long. Discharging and adding catalysts at once results in high maintenance costs, a large amount of on-site work, and is time-consuming and labor-intensive.

[0004] (2) Temporary treatment: There are two valves at the bottom of the normal reactor, and the two valves are connected by a short circuit. To replace the lower valve, you only need to close the upper valve. However, when replacing the first manual valve, the pipeline is full of catalyst. If the operation is not done properly, there is a risk of large catalyst leakage that cannot be blocked. Direct replacement involves inserting a thin iron plate into the flange or other filler into the flange pipeline to block it. It is difficult to clean the catalyst in the octagonal concave groove sealing surface of the valve and flange, difficult to remove the filler, and difficult to reinstall the valve. It is easy to cause leakage danger when starting up the temperature and pressure (the medium in the pipeline is hydrogen).

[0005] Therefore, there is currently a lack of a safe and efficient valve replacement solution. Utility Model Content

[0006] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a simple and easy-to-use special valve changer that can better replace and handle valves, solve the problem of difficult flange surface cleaning during valve replacement, minimize catalyst loss, and ensure stable operation of the equipment.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0008] Online valve replacement fixtures, including:

[0009] An octagonal gasket displacement fixture is installed on an octagonal gasket on a valve flange. The octagonal gasket displacement fixture is held against the octagonal gasket by a set screw and is used to move the octagonal gasket and adjust the gap between the octagonal gasket and the valve flange or pipeline flange.

[0010] The split sealing plate is used to eject the octagonal gasket and is assembled in the gap between the valve flange and the pipeline flange. The split sealing plate is equipped with a split plugging seal shaft to seal the inner cavity of the pipeline flange.

[0011] A valve plugging mounting bracket is fixed to the pipeline and connected to the split-type plugging shaft via a central threaded screw. The bracket supports the pipeline and the split-type plugging shaft when the valve is removed.

[0012] Furthermore, the octagonal gasket displacement fixture includes two semi-circular ring fixing rings, each with a connecting lug. A fixture connecting bolt is threaded onto the connecting lug. The two semi-circular ring fixing rings are fixed to the outside of the valve flange and pipeline flange via the connecting lug and the fixture connecting bolt. The two fixing rings have several radial internal threaded holes, and the set screws are connected to the internal threaded holes. The set screws abut against the octagonal gasket.

[0013] Furthermore, the split sealing plate includes a sealing plate and a positioning arc plate disposed at one end of the sealing plate. The sealing plate is assembled in the gap between the valve flange and the pipeline flange, while simultaneously pushing out the octagonal gasket. The sealing plate has a recessed assembly groove in the middle, and the split-type plugging seal shaft is movably assembled in the assembly groove. A through hole is formed at the bottom of the assembly groove for the central through threaded rod to pass through. The split-type plugging seal shaft can detach from the sealing plate axially from the top of the assembly groove. The sealing plate is provided with a positioning internal threaded hole for connecting the pipeline flange. The positioning arc plate is positioned in conjunction with the outer circumferential surface of the pipeline flange.

[0014] Furthermore, the split-type plugging seal shaft is configured with a tapered structure, and a circular silicone plate is provided at the bottom of the split-type plugging seal shaft. The silicone plate is pressed by a pressure pad and fixed by a pressure bolt. The split-type plugging seal shaft is provided with a connecting internal thread hole with a bottom opening. The silicone plate and the pressure pad are formed with a central hole corresponding to the connecting internal thread hole. The connecting internal thread hole is used to connect the central through thread screw. The side surface of the pressure pad is provided with a circumferential positioning mechanism fixed in the circumferential direction of the sealing plate. When the split-type plugging seal shaft, silicone plate and pressure pad are connected to form an integral seal for the inner cavity of the pipeline flange, the silicone plate is interference-fitted with the inner cavity of the pipeline flange.

[0015] Furthermore, the clamping bolt is a countersunk bolt.

[0016] Furthermore, the end face of the sealing plate away from the positioning arc plate is set as an arc-shaped surface, and the arc-shaped surface fits into the outer peripheral surface of the octagonal pad; the sealing plate is provided with four positioning internal threaded holes, which are respectively located at the four corners of the sealing plate, and the four positioning internal threaded holes correspond one-to-one with four bolt holes of the pipeline flange; the circumferential positioning mechanism is a convex locking block extending radially on the side surface of the pressure pad, and the sealing plate is provided with a positioning groove adapted to the convex locking block, and the upper surface of the positioning groove is connected to the assembly groove.

[0017] Furthermore, the valve plugging mounting bracket also includes a pipe clamp fixture, a support screw, an upper pressure plate, and a lower pressure plate. The pipe clamp fixture is fixed to the pipeline, and the support screw is connected to the pipe clamp fixture. Two screw nuts are threaded onto the center through-thread screw. Rotating the screw nuts causes the center through-thread screw to move linearly. A pressure plate support nut is threaded onto the support screw. The upper and lower pressure plates are U-shaped pressure plates with open elongated holes. The upper and lower pressure plates are respectively assembled onto the support screw and the center through-thread screw through the open elongated holes. The pressure plate support nut locks the upper and lower pressure plates under the two screw nuts. The upper and lower pressure plates provide support for the center through-thread screw. The process of disassembling and installing the center through-thread screw inside the valve is carried out by alternately removing the upper and lower pressure plates.

[0018] Furthermore, there are two support screws, located on both sides of the central through screw. The central through screw and the two support screws are arranged side by side on the same plane. The central through screw is provided with two screw nuts, and each support screw is provided with two pressure plate support nuts. Through the pressure plate support nuts on the two support screws, the upper pressure plate and the lower pressure plate are locked from bottom to top to the area below the two screw nuts.

[0019] Furthermore, the upper part of the central threaded screw is connected to a reinforcing cap for supporting the bottom of the split-type plug seal shaft.

[0020] Furthermore, the pipe clamping fixture includes two semi-circular retaining rings, which are fixed to the outer wall of the pipeline and locked with retaining ring bolts. A support plate is fixed on the retaining rings, and the support plate is provided with a screw connection through hole for connecting the support screw.

[0021] The replacement method using the above-mentioned online valve replacement fixture includes the following steps:

[0022] Step S100: Install the octagonal gasket relocation fixture; There are a total of eight flange bolts between the valve flange and the pipeline flange. Remove four of the flange bolts, loosen the remaining four flange bolts, install the two semi-circular ring fixing rings on the outside of the valve flange and the pipeline flange, tighten the two fixture connecting bolts to make the two semi-circular ring fixing rings form a whole, adjust the set screw on the relocation fixture to lock it on the octagonal gasket, move the fixture to move the octagonal gasket to the middle position of the valve flange and the pipeline flange, so that the gap between the two flanges is greater than the thickness of the sealing plate, and remove the octagonal gasket relocation fixture;

[0023] Step S200: Install the sealing plate; push the sealing plate between the valve flange and the pipeline flange, while the sealing plate pushes the octagonal gasket out of the flange. The positioning arc plate on the sealing plate is tightly fitted with the outer circumference of the pipeline flange. At this time, the split plug seal shaft is in the middle of the pipeline flange; connect the four positioning internal threaded holes of the sealing plate and the four bolt holes left by removing the flange bolts of the pipeline flange through the four sealing plate connecting bolts, so that the sealing plate and the pipeline flange form an integrated closed structure;

[0024] Step S300: Remove the valve; remove the remaining four flange bolts to detach the valve from the pipeline flange, and remove the lower valve;

[0025] Step S400: Install the valve plugging mounting bracket; fix the pipe clamp fixture to the outer wall of the pipeline, and drive the split plugging shaft and silicone plate into the pipeline flange for plugging through the center through threaded screw. Install the upper pressure plate and lower pressure plate under the two screw nuts respectively, and tighten them through the pressure plate support nuts to fix the center through threaded screw.

[0026] Step S500: Remove the sealing plate; remove the four sealing plate connecting bolts, pull out the upper pressure plate, push the sealing plate back along the center threaded screw to the upper part of the lower pressure plate, install the upper pressure plate, rotate and adjust the upper pressure plate support nut, hold the upper pressure plate against the lower part of the upper screw nut, lock the upper pressure plate, support the center threaded screw to prevent the split-type plugging seal shaft from sinking, pull out the lower pressure plate, and remove the sealing plate;

[0027] Step S600: Install the valve; clean the sealing surface of the pipeline flange, place the octagonal gasket, repaired valve or new valve sealing plate into the valve plug mounting bracket along the center threaded screw, install the lower pressure plate, rotate and adjust the lower pressure plate support nut to hold the lower pressure plate against the lower threaded screw nut, lock the lower pressure plate, support the center threaded screw to prevent the split plug shaft from sinking, pull out the upper pressure plate, align the octagonal gasket, valve flange with the pipeline flange, and install and tighten the flange bolts;

[0028] Step S700: Remove the tooling; rotate the upper screw nut to make the center threaded screw drive the split plug seal shaft and silicone plate to the lower part of the valve plate, close the valve, and remove the valve plug mounting bracket.

[0029] Further, in step S100, remove the four flange bolts at the front and back of the valve handle, loosen the remaining four flange bolts on both sides by 5mm, check if the octagonal gasket is stuck in the upper and lower grooves of the flange opening, tap to loosen it, install the octagonal gasket relocation tool, continue to loosen the remaining four flange bolts until the gap between the two flanges is greater than the thickness of the sealing plate, keep the octagonal gasket in the middle position of the upper and lower flange openings, rotate the octagonal gasket until the lower flange opening groove is filled with catalyst, and remove the octagonal gasket relocation tool.

[0030] Furthermore, in step S400, when installing the valve plugging mounting bracket, only the lower pressure plate is installed. The upper pressure plate is then installed after the sealing plate moves above the lower pressure plate.

[0031] Furthermore, in step S600, after cleaning and repairing the pipeline flange sealing surface, the new valve or the valve plate of the repaired valve is in the fully open state.

[0032] Furthermore, the replacement method of the line valve replacement tool is used to replace the pipeline valve; the pipeline has two valves for control, and the two valves are connected by a short circuit. When replacing the first valve, the tool acts on the first valve. In the process of removing the valve in step S300, the first valve, the ground ring and the second valve under the sealing plate are completely removed.

[0033] The beneficial effects of this utility model are as follows: This utility model can solve the problem of difficult flange surface cleaning when replacing valves, minimize catalyst loss, and fundamentally solve the leakage problem caused by factors such as full pipeline catalyst, improper operation, large catalyst leakage, and inability to seal. Attached Figure Description

[0034] Figure 1 To improve the pipeline valve assembly structure diagram;

[0035] Figure 2 Schematic diagram of the installation of the octagonal pad relocation fixture;

[0036] Figure 3 Top view of the octagonal pad displacement fixture;

[0037] Figure 4 This is a schematic diagram of the installation of the split sealing plate;

[0038] Figure 5 for Figure 4 Enlarged view of the split-type sealing plate;

[0039] Figure 6 This is a top view of the sealing plate structure;

[0040] Figure 7 This is a schematic diagram of the sealing plate connection assembly;

[0041] Figure 8 Top view of the sealing plate connection assembly;

[0042] Figure 9 Assembly drawing for valve plugging mounting bracket;

[0043] Figure 10 This is a schematic diagram of the pipe clamp tooling;

[0044] Figure 11 This is a schematic diagram of the upper and lower pressure plates.

[0045] Figure 12 Valve plugging mounting bracket operation diagram Figure 1 ;

[0046] Figure 13 Operation diagram of valve plugging mounting bracket Figure 2 ;

[0047] Figure 14 for Figure 13 Side view;

[0048] Figure 15 Valve installation and operation Figure 1 ;

[0049] Figure 16 Valve installation and operation Figure 2 ;

[0050] Figure 17 Valve installation and operation Figure 3 ;

[0051] In the diagram: 1. Valve, 2. Catalyst, 3. Pipeline, 4. Octagonal gasket displacement fixture, 401. Set screw, 402. Fixture connecting bolt, 403. Internal threaded hole, 404. Retaining ring, 405. Connecting lug, 5. Pipeline flange, 501. Pipeline flange bolt hole, 6. Valve flange, 7. Octagonal gasket, 8. Split sealing plate, 801. Split plugging seal shaft, 802. Countersunk bolt, 803. Connecting internal threaded hole, 804. Silicone plate, 805. Circumferential positioning mechanism, 806. Positioning internal threaded hole, 807. Positioning arc plate, 808. Sealing plate, 809. Pressure pad, 9. Sealing plate connecting bolt, 10. Valve plugging mounting bracket, 1001. Pipe clamp fixture, 1002. Center threaded rod, 1003. Reinforcing cap. 1004. Upper pressure plate; 1005. Screw and nut; 1006. Lower pressure plate; 1007. Support screw; 1008. Pressure plate support nut. Detailed Implementation

[0052] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0053] See appendix Figure 1-17 To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0054] Online valve replacement fixtures include an octagonal gasket displacement fixture 4, a split sealing plate 8, and a valve plugging mounting bracket 10;

[0055] The octagonal gasket displacement fixture 4 is installed on the octagonal gasket 7 at the valve flange opening. The octagonal gasket displacement fixture is held against the octagonal gasket 7 by the set screw 401. It is used to move the octagonal gasket 7 and adjust the gap between the octagonal gasket 7 and the valve flange opening and the pipeline flange opening. This loosens the octagonal gasket and makes the gap between the valve flange and the pipeline flange slightly larger than the thickness of the sealing plate.

[0056] Specifically, the octagonal gasket displacement fixture 4 includes two semi-circular ring fixing rings 404. The two semi-circular ring fixing rings 404 are provided with connecting lugs 405. The connecting lugs 405 are threaded with fixture connecting bolts 402. The two semi-circular ring fixing rings 404 are connected and fixed to the outside of the valve flange 6 and the pipeline flange 5 through the connecting lugs 405 and fixture connecting bolts 402. The two fixing rings 404 are provided with four radial internal threaded holes 403. The internal threaded holes 403 are connected with set screws 401. The four set screws 401 abut against the octagonal gasket 7.

[0057] Based on the above technical solution, the octagonal gasket displacement fixture 4 plays the role of adjusting the position of the octagonal gasket 7 inside the flange, so that the octagonal gasket 7 is in the middle position of the loosened flange, and the size between the valve flange and the pipeline flange can not only meet the passage of the sealing plate 808, but also prevent the pipeline catalyst from flowing out.

[0058] The assembly and usage process is as follows: The octagonal gasket displacement fixture 4 can be installed on the octagonal gasket 7 at the flange opening to finely adjust the gap between the octagonal gasket and the flange opening, preventing excessive gap and catalyst leakage. Before loosening the flange bolts, mark the end face of the octagonal gasket and the flange plane. There are a total of eight bolts on the flange. Remove the four bolts before and after the valve handle, and loosen the remaining four bolts on both sides by about 5mm. Check if the octagonal gasket is stuck in the upper and lower grooves of the flange opening. After loosening it by tapping, install the octagonal gasket displacement fixture, and at the same time continue to loosen the remaining four bolts to keep the octagonal gasket in the middle position of the upper and lower flange openings. Gently rotate the octagonal gasket until the lower flange opening groove is filled with catalyst, and then remove the octagonal gasket displacement fixture.

[0059] The split sealing plate 8 is used to eject the octagonal gasket 7 and is assembled in the gap between the valve flange and the pipeline flange. The split sealing plate 8 is provided with a split plugging sealing shaft 801 for sealing the inner cavity of the pipeline flange.

[0060] Specifically, the split sealing plate 8 includes a sealing plate 808 and a positioning arc plate 807 disposed at one end of the sealing plate 808. The sealing plate 808 is assembled in the gap between the valve flange and the pipeline flange, while pushing out the octagonal gasket 7. The sealing plate has a concave assembly groove in the middle. The split plugging sealing shaft 801 is movably assembled in the assembly groove. The split plugging sealing shaft 801 is not higher than the upper surface of the sealing plate 808 to avoid affecting the assembly of the sealing plate between the valve flange and the pipeline flange.

[0061] Furthermore, a through hole is formed at the bottom of the assembly groove for the central through screw 1002 to pass through. The central through screw 1002 is connected to the split plugging seal shaft 801 in the assembly groove, and the split plugging seal shaft 801 is controlled to detach from the sealing plate 808 axially from the top of the assembly groove.

[0062] Furthermore, the split-type plugging seal shaft 801 is configured with a conical structure. A circular silicone plate 804 is positioned at the bottom of the split-type plugging seal shaft 801. The silicone plate 804 is pressed against the bottom by a pressure pad 809 and fixed by countersunk bolts 802. Behind the lower silicone plate 804, another pressure pad 809 is connected and pressed together by two countersunk bolts 802, ensuring that the silicone plate 804 is not easily detached. The split-type plugging seal shaft 801, silicone plate 804, and pressure pad 809 are connected by two countersunk bolts 802 to form a single unit. The diameter of the silicone plate 804 is slightly larger than the inner diameter of the pipeline flange, utilizing the elastic deformation capacity of the silicone plate 804 to seal the pipeline flange. The diameter of the pressure pad 809 is smaller than the diameter of the silicone plate 804. The assembly groove supports the lower surface of the silicone plate 804, and the pressure pad 809 is located within a through hole at the bottom of the assembly groove.

[0063] Based on the above technical solution, the split-type plugging seal shaft 801, silicone plate 804, and pressure gasket 809 are connected to form a whole. When sealing the inner cavity of the pipeline flange, the silicone plate 804 is press-fitted with the inner cavity of the pipeline flange. The sealing plate 808 acts as a temporary blind cover to prevent catalyst flow and overflow. The split-type plugging seal shaft 801 is supported by the valve plugging mounting bracket 10, allowing the split-type plugging seal shaft to enter the pipeline flange 5 to prevent catalyst outflow. Removing the sealing plate 808 allows for a clearer inspection and repair of the upper flange sealing surface.

[0064] Furthermore, the split-type plugging seal shaft 801 is provided with a bottom-opening internal threaded hole 803, which is used to be threadedly connected to the central through-thread screw 1002. The silicone plate 804 and the pressure pad 809 have central holes corresponding to the internal threaded hole. The central through-thread screw 1002 passes through the through hole of the sealing plate 808, the central hole of the pressure pad 809 and the central hole of the silicone plate 804 in sequence and is connected to the internal threaded hole 803 of the split-type plugging seal shaft 801.

[0065] Based on the above technical solution, the split-type plugging seal shaft 801 is designed with a conical structure to reduce friction. The lower part has a circular silicone plate 804 to prevent the catalyst from leaking downwards. The bottom is provided with a connecting internal thread hole 803 for adjusting the center through thread screw 1002 up and down. Due to the limited gap of the flange opening, the sealing plate is pushed into the flange opening before connecting the center through thread screw 1002.

[0066] Furthermore, the sealing plate 808 is provided with four positioning internal threaded holes 806 for connecting the pipeline flange 5, located at the four corners of the sealing plate 808. Each of the four positioning internal threaded holes 806 corresponds one-to-one with the four flange bolt holes on the front and rear of the pipeline flange handle. The diameter and spacing of the positioning internal threaded holes 806 are consistent with the diameter and spacing of the holes in the pipeline flange 5. The sealing plate 808 is connected and fixed to the pipeline flange 5 by sealing plate connecting bolts 9.

[0067] Furthermore, the positioning arc plate 807 is positioned in conjunction with the outer circumferential surface of the pipeline flange.

[0068] Furthermore, the end face of the sealing plate 808 away from the positioning arc plate is set as an arc-shaped surface, and the arc-shaped surface is in contact with the outer peripheral surface of the octagonal pad 7, which can smoothly push out the octagonal pad.

[0069] Furthermore, a circumferential positioning mechanism 805 is provided on the side surface of the pressure pad 809, which is fixed to the circumference of the sealing plate 808, so that the pressure pad 809 and the sealing plate 808 are connected as one in the circumferential direction. This prevents the split-type plugging sealing shaft 801 from rotating synchronously and the center through-thread screw 1002 from disengaging when the center through-thread screw 1002 is screwed into the connecting inner thread hole 803 of the split-type plugging sealing shaft 801.

[0070] In one embodiment, the circumferential positioning mechanism is a convex locking block extending radially on the side surface of the pressure pad 809. The sealing plate 808 is provided with a positioning groove adapted to the convex locking block. The convex locking block is tightly connected to the positioning groove of the sealing plate, so that the split-type plugging seal shaft 801 and the sealing plate 808 are integrated in the circumferential direction, preventing the split-type plugging seal shaft 801 from rotating. When rotating the center through screw 1001, the center through screw 1001 is not easily disengaged due to the locking of the convex groove. The upper surface of the positioning groove communicates with the assembly groove, facilitating the convex locking block to detach from the sealing plate above the positioning groove.

[0071] In another embodiment, the circumferential positioning mechanism is provided with positioning pin holes corresponding to the side surface of the pressure pad 809 and the sealing plate 808. Positioning pins for positioning the split-type plugging seal shaft 801 and the sealing plate 808 are installed in the positioning pin holes. The positioning pins make the split-type plugging seal shaft 801 and the sealing plate 808 form an integral part in the circumferential direction, preventing the split-type plugging seal shaft 801 from rotating. The upper surface of the positioning pin hole is connected to the assembly groove, so that the positioning pin and the positioning pin hole can be quickly separated when the split-type plugging seal shaft 801 is longitudinally displaced.

[0072] The assembly and use process is as follows: Push the split sealing plate 8 into the gap between the valve flange and the pipeline flange, push out the octagonal gasket 7, connect the four positioning internal threaded holes 806 of the sealing plate to the valve flange, tighten the four sealing plate connecting bolts 9, open the second valve, discharge the catalyst at the bottom of the split sealing plate 8 into the lifting tank, remove the remaining four bolts connecting the valve flange 6 and the pipeline flange 7, remove the valve, ground ring and other components under the sealing plate, leaving the assembly space for the valve plug mounting bracket, install the valve plug mounting bracket 10, tighten the center through thread 1002 and the upper pressure plate and upper pressure plate support nut.

[0073] The valve plugging mounting bracket 10 is fixed to the pipeline. The valve plugging mounting bracket 10 is connected to the split plugging shaft 801 through the center through screw 1002, and supports the pipeline and the split plugging shaft 801 when the valve is removed.

[0074] Specifically, the valve plugging mounting bracket includes a central through-thread screw 1002, a pipe clamp fixture 1001, a support screw 1007, an upper pressure plate 1004, and a lower pressure plate 1006. The pipe clamp fixture 1001 is fixed to the pipeline, and the support screw 1007 is connected to the pipe clamp fixture 1001. Two screw nuts 1005 are threaded onto the central through-thread screw 1001. Rotating the upper screw nut causes the central through-thread screw 1002 to move linearly. Two pressure plate support nuts 1008 are threaded onto the support screw 1007. The pressure plate support nuts 1008 lock the upper pressure plate 1004 and the lower pressure plate 1006 below the two screw nuts 1005 respectively. The upper pressure plate 1004 and the lower pressure plate 1006 together provide support for the central through-thread screw 1002. Rotate the upper screw and nut in the opposite direction to move the center threaded screw 1002 upward. The center threaded screw 1002 on the upper pressure plate is lengthened, which drives the split-type plugging seal shaft 801 into the pipeline flange 5. The silicone plate 804 below the split-type plugging seal shaft 801 blocks the pipeline flange opening, preventing the catalyst in the pipeline from leaking out. The split-type plugging seal shaft 801 separates from the sealing plate 808.

[0075] Furthermore, there are two support screws 1007, located on both sides of the central through screw 1002. The central through screw 1002 and the two support screws 1007 are arranged side by side on the same plane. The upper pressure plate 1004 and the lower pressure plate 1006 are locked onto the central through screw 1002 and the two support screws 1007 to ensure the stability of the valve plugging mounting bracket. Two screw nuts 1005 are provided on the central through screw 1002, and two pressure plate support nuts 1008 are provided on each support screw. Through the pressure plate support nuts 1008 on the two support screws 1007, the upper pressure plate 1004 and the lower pressure plate 1005 are locked from bottom to top below the two screw nuts 1005.

[0076] Furthermore, the upper pressure plate 1004 and the lower pressure plate 1005 are U-shaped pressure plates with open elongated holes. The upper pressure plate 1004 and the lower pressure plate 1006 are respectively assembled onto the two support screws 1007 and the center through screw 1002 through the open elongated holes. The disassembly and installation process of the valve through the center through screw 1002 is carried out by alternately removing the upper pressure plate 1004 and the lower pressure plate 1006.

[0077] Based on the above technical solution, the upper pressure plate 1004 and the lower pressure plate 1005 are designed with a rectangular open side for easy removal from the side. After removing the four sealing plate connecting bolts 9 connecting the sealing plate 808 to the pipeline flange, the sealing plate 808 is moved to the upper part of the lower pressure plate 1006. The upper pressure plate 1004 is then installed, the upper pressure plate support nut is adjusted, the lower pressure plate 1006 is removed, and the sealing plate 808 is taken out. The valve plugging mounting bracket 10, by swapping the upper pressure plate 1004 and the lower pressure plate 1006, allows the split-type plugging shaft 801 to enter the pipeline flange 5 for plugging. The sealing plate is then removed to inspect the sealing surface, and the valve is installed.

[0078] Furthermore, the upper part of the central through screw 1002 is connected to a reinforcing cap 1003 for supporting the bottom of the split-type plugging seal shaft 801. The diameter of the through hole below the sealing plate assembly groove is larger than the diameter of the reinforcing cap 1003, so that the reinforcing cap 1003 can pass through the sealing plate 808.

[0079] Furthermore, the pipe clamping fixture 1001 includes two semi-circular retaining rings, which are fixed to the outer wall of the pipeline and locked by retaining ring bolts. A support plate is fixed on the retaining rings, and the support plate is provided with a screw connection through hole for connecting the support screw 1007.

[0080] The valve operation is as follows: After cleaning and repairing the pipeline flange sealing surface, the new valve to be replaced or the repaired valve plate is in the fully open position. The new octagonal gasket and valve cavity are moved to the lower part of the upper pressure plate 1004 along the center threaded screw 1002. The lower pressure plate 1006 is inserted, and the lower pressure plate support nut is adjusted (at this time, the upper part of the lower pressure plate is locked by the screw nut 1005, and the lower part of the lower pressure plate is locked by the lower pressure plate support nut, which is used to control the speed of pulling the center threaded screw). The upper pressure plate 1004 is pulled out, and the bolts connecting the valve flange and the pipeline flange are connected. The screw nut of the lower pressure plate is rotated to shorten the center threaded screw 1002 on the upper part of the lower pressure plate 1006. The upper part of the center threaded screw 1002 is moved back to the lower part of the valve plate. The valve plate is closed, and the upper part of the center threaded screw 1002 is moved back to the outside of the lower flange of the valve. The upper and lower pressure plates are removed, and the valve sealing mounting bracket is removed. This work is completed.

[0081] See appendix Figure 1-17 The replacement method using the above-mentioned online valve replacement fixture includes the following steps:

[0082] Step S100: Install the octagonal pad relocation fixture

[0083] There are a total of eight flange bolts between valve flange 6 and pipeline flange 5. Before loosening the flange bolts, mark the end face of the octagonal gasket 7 and the flange plane. Remove the four flange bolts before and after the valve handle. Loosen the remaining four flange bolts on both sides by 5mm. Check if the octagonal gasket 7 is stuck in the upper and lower grooves of the flange opening. After loosening it by tapping, install the octagonal gasket displacement tool 4. Install the two semi-circular ring fixing rings 404 on the outside of valve flange 6 and pipeline flange 5. Tighten the two tool connecting bolts 402 to make the two semi-circular ring fixing rings 404 form a whole. Adjust the four set screws 401 on the displacement tool to be stuck on the octagonal gasket 7. Move the tool to move the octagonal gasket 7 to the middle position between valve flange 6 and pipeline flange 5. Continue to loosen the remaining four flange bolts until the gap between the two flanges is greater than the thickness of the sealing plate 808. Keep the octagonal gasket 7 in the middle position between the upper and lower flange openings. Rotate the octagonal gasket 7 until the lower valve flange opening groove is filled with catalyst. Remove the octagonal gasket displacement tool 4.

[0084] Step S200: Install the sealing plate

[0085] The sealing plate 808 is pushed between the valve flange 6 and the pipeline flange 5. At the same time, the sealing plate 808 pushes the octagonal gasket 7 out of the flange. The positioning arc plate 807 on the sealing plate is tightly fitted with the outer circumference of the pipeline flange. At this time, the split plugging seal shaft 801 is in the middle of the pipeline flange 5. The four positioning internal threaded holes 806 of the sealing plate and the four bolt holes left by the removal of the flange bolts of the pipeline flange are connected by four sealing plate connecting bolts 9, so that the sealing plate 808 and the pipeline flange 5 form an integrated closed structure.

[0086] Step S300: Remove the valve

[0087] Remove the remaining four flange bolts through the pipeline flange to detach the valve from the pipeline flange 5, and remove the valve, ground ring, and second valve at the bottom of the sealing plate 8.

[0088] Step S400: Install the valve plugging mounting bracket

[0089] Fix the pipe clamp fixture 1001 to the outer wall of the pipeline. Rotate the adjusting screw nut 1005. The split plugging shaft 801 and silicone plate 804 are driven into the pipeline flange 5 for sealing through the center through screw nut 1002. The upper pressure plate 1004 and the lower pressure plate 1006 are respectively installed below the two screw nuts 1005 and pressed by the two sets of pressure plate support nuts 1008 to fix the center through screw nut 1002.

[0090] Step S500: Remove the sealing plate

[0091] Adjust the lower pressure plate 1004 and the upper pressure plate 1006 to lock synchronously, remove the four sealing plate connecting bolts 9, pull out the upper pressure plate 1004, and push the sealing plate back along the center threaded screw 1002 to the upper part of the lower pressure plate 1004. Install the upper pressure plate 1004, rotate and adjust the upper pressure plate support nut, and hold the upper pressure plate against the lower part of the upper screw nut. Lock the upper pressure plate 1004, support the center threaded screw 1002, so that the split-type plugging seal shaft 801 does not sink. Pull out the lower pressure plate 1006 and remove the sealing plate 808.

[0092] Step S600: Install valves

[0093] Clean the sealing surface of the pipeline flange, and put the valve plate of the new or repaired valve in the fully open position. Place the octagonal gasket, the repaired valve or the new valve sealing plate into the valve plugging mounting bracket 10 along the center threaded screw 1002. Install the lower pressure plate 1006, rotate and adjust the lower pressure plate support nut to hold the lower pressure plate against the lower threaded screw nut, lock the lower pressure plate 1006, support the center threaded screw 1002 to prevent the split plugging seal shaft 801 from sinking, pull out the upper pressure plate 1004, align the octagonal gasket, valve flange with the pipeline flange, install the flange bolts and tighten them.

[0094] Step S700: Remove tooling

[0095] Rotate the upper screw nut to make the center threaded screw 1002 drive the split plugging seal shaft 801 and silicone plate 804 to the lower part of the valve plate, close the valve, remove the valve plugging mounting bracket 10, and the replacement is complete.

[0096] Furthermore, in step S400, when installing the valve plugging mounting bracket, only the lower pressure plate 1005 needs to be installed. After the sealing plate 808 moves above the lower pressure plate 1005, the upper pressure plate 1004 is then installed, simplifying the operation steps.

[0097] Furthermore, the replacement method of the line valve replacement tool is used to improve the replacement of pipeline valves; the pipeline has two valves for control, and the two valves are connected by a short circuit in the middle, and the tool is applied to the first valve.

[0098] Furthermore, the hole spacing and hole diameter of the positioning internal threaded hole 806 of the sealing plate, the pipeline flange connection hole, and the valve flange connection hole are the same.

[0099] This invention reduces catalyst loss during valve replacement. It involves loosening flange bolts, adjusting the octagonal gasket between flanges, inserting the sealing plate (catalyst spillage during this process is limited to the amount stored in the octagonal gasket and collected via a plastic bag), installing the sealing plate connecting bolts, removing the first and second valves for repair or replacement, connecting the valve plugging mounting bracket, rotating the screw and nut to allow the split-type plugging seal shaft to enter the pipeline flange, removing the sealing plate, and more clearly inspecting and repairing the upper flange sealing surface. This effectively prevents re-leakage and safety hazards caused by inadequate sealing surface treatment. The valve is then installed in a fully open state. The split-type plugging seal shaft is pulled out to the bottom of the valve plate, the valve is closed, and the split-type plugging seal shaft is pulled out again (catalyst spillage during this process is limited to the amount stored between the upper plugging shaft and the valve plate).

[0100] It should be noted that the parts of this utility model not described in detail are existing technologies.

[0101] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0102] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0103] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0104] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0105] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0106] The above-listed embodiments are merely preferred embodiments of this utility model. Obviously, this utility model is not limited to the above embodiments and many variations are possible. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of this utility model should be considered within the protection scope of this utility model.

Claims

1. An online valve replacement fixture, characterized in that, include: An octagonal gasket displacement fixture is installed on an octagonal gasket on a valve flange. The octagonal gasket displacement fixture is held against the octagonal gasket by a set screw and is used to move the octagonal gasket and adjust the gap between the octagonal gasket and the valve flange or pipeline flange. The split sealing plate is used to eject the octagonal gasket and is assembled in the gap between the valve flange and the pipeline flange. The split sealing plate is equipped with a split plugging seal shaft to seal the inner cavity of the pipeline flange. A valve plugging mounting bracket is fixed to the pipeline and connected to the split-type plugging shaft via a central threaded screw. The bracket supports the pipeline and the split-type plugging shaft when the valve is removed.

2. The online valve replacement fixture according to claim 1, characterized in that, The octagonal gasket displacement fixture includes two semi-circular fixing rings. The two semi-circular fixing rings are provided with connecting lugs, and the connecting lugs are threaded with fixture connecting bolts. The two semi-circular fixing rings are connected and fixed to the outside of the valve flange and pipeline flange through the connecting lugs and fixture connecting bolts. The two fixing rings are provided with a plurality of radial internal threaded holes, and the internal threaded holes are connected with the set screws. The plurality of set screws abut against the octagonal gasket.

3. The online valve replacement fixture according to claim 1, characterized in that, The split sealing plate includes a sealing plate and a positioning arc plate disposed at one end of the sealing plate. The sealing plate is assembled in the gap between the valve flange and the pipeline flange, while simultaneously pushing out the octagonal gasket. The sealing plate has a recessed assembly groove in the middle, and the split plugging seal shaft is movably assembled in the assembly groove. The bottom of the assembly groove has a through hole for the central through threaded rod to pass through. The split plugging seal shaft can detach from the sealing plate axially from the top of the assembly groove. The sealing plate is provided with a positioning internal threaded hole for connecting the pipeline flange. The positioning arc plate is positioned in conjunction with the outer circumferential surface of the pipeline flange.

4. The online valve replacement fixture according to claim 3, characterized in that, The split-type plugging seal shaft is designed with a tapered structure. A circular silicone plate is provided at the bottom of the split-type plugging seal shaft. The silicone plate is pressed tightly by a pressure pad and fixed by a pressure bolt. The split-type plugging seal shaft is provided with a connecting internal thread hole with a bottom opening. The silicone plate and the pressure pad are formed with a central hole corresponding to the connecting internal thread hole. The connecting internal thread hole is used to connect the central threaded screw. A circumferential positioning mechanism fixed to the circumference of the sealing plate is provided on the side surface of the pressure pad. When the split-type plugging seal shaft, silicone plate and pressure pad are connected to form a whole to seal the inner cavity of the pipeline flange, the silicone plate is interference-fitted with the inner cavity of the pipeline flange.

5. The online valve replacement fixture according to claim 4, characterized in that, The circumferential positioning mechanism is a convex locking block extending radially on the side surface of the pressure pad. The sealing plate is provided with a positioning groove that matches the convex locking block. The upper surface of the positioning groove is connected to the assembly groove.

6. The online valve replacement fixture according to claim 3, characterized in that, The end face of the sealing plate away from the positioning arc plate is set as an arc-shaped surface, and the arc-shaped surface fits into the outer peripheral surface of the octagonal gasket; the sealing plate is provided with four positioning internal threaded holes, which are located at the four corners of the sealing plate respectively, and the four positioning internal threaded holes correspond one-to-one with four bolt holes of the pipeline flange.

7. An online valve replacement fixture according to any one of claims 1-6, characterized in that, The valve plugging mounting bracket also includes a pipe clamp fixture, a support screw, an upper pressure plate, and a lower pressure plate. The pipe clamp fixture is fixed to the pipeline, and the support screw is connected to the pipe clamp fixture. A screw nut is threaded onto the center through screw. Rotating the screw nut causes the center through screw to move linearly. A pressure plate support nut is threaded onto the support screw. The upper and lower pressure plates are locked onto the support screw and the center through screw through by the pressure plate support nut.

8. The online valve replacement fixture according to claim 7, characterized in that, The upper and lower pressure plates are U-shaped pressure plates with open elongated holes. The upper and lower pressure plates are respectively assembled onto the support screw and the center through screw through the open elongated holes. The pressure plate support nut locks the upper and lower pressure plates under the two screw nuts respectively. The upper and lower pressure plates provide support for the center through screw. The disassembly and installation process of the valve through the center through screw is carried out by alternately removing the upper and lower pressure plates.

9. The online valve replacement fixture according to claim 7, characterized in that, There are two support screws, located on both sides of the central through screw. The central through screw and the two support screws are arranged side by side on the same plane. The central through screw has two screw nuts, and each support screw has two pressure plate support nuts. The upper pressure plate and the lower pressure plate are locked to the bottom of the two screw nuts from bottom to top through the pressure plate support nuts on the two support screws.

10. The online valve replacement fixture according to claim 7, characterized in that, The pipe clamping fixture includes two semi-circular retaining rings, which are fixed to the outer wall of the pipeline and locked with retaining ring bolts. A support plate is fixed on the retaining rings, and the support plate is provided with a screw connection through hole for connecting the support screw.

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