Complete pressing unit of intelligent pressure test control system

Abstract

The utility model discloses a complete pressurizing unit of an intelligent pressure test control system. The complete pressurizing unit comprises a test water tank, a surge tank, an underground water tank and an intelligent control cabinet, the test water tank provides a constant-pressure water source for the surge tank through the reciprocating pump, and the surge tank is connected with the detachable plate heat exchangers through multiple groups of parallel branches to realize synchronous water injection, pressure boosting and pressure maintaining; the underground water tank forms an external circulation system through the soft water settling tank, the sand tank and the blue dirt separator, and the centrifugal pump is combined to filter, recycle and reuse the softened water; the intelligent control cabinet integrates a PLC and an HMI touch screen, regulates and controls pressure, temperature and water flow balance in real time, automatically generates a pressure test data report and stores the pressure test data report to a computer operation end. Through multi-branch synchronous operation, closed-loop water circulation and full-automatic control, the pressure testing efficiency is improved to 6 times that of manual operation, the repeated utilization rate of softened water reaches 95%, water resource waste and manual intervention risks are remarkably reduced, and the device has the advantages of being efficient, safe and environmentally friendly.

Description

Technical Field

[0001] This utility model relates to the field of pressure testing equipment technology, specifically to an intelligent pressure testing control system complete pressure testing unit. Background Technology

[0002] Detachable plate heat exchangers must undergo a water pressure test before leaving the factory (the water pressure test of most products is within 4.0 MPa). The existing equipment mainly uses local manual pressure testing pumps to control individual pressure pump equipment. The main problems with the pressure testing method are as follows: (1) The existing individual pressure pumps have a low degree of automation and intelligence; (2) The pressure testing process is manually controlled by the operators, and the pressure test report is a paper version filled out manually. The human resources investment is large but the production efficiency is low. During the peak period, the monthly production is 300 units, and the daily production is 10 units. The pressure testing time for a single unit is 2 to 3 hours / 2 people, and the existing equipment can only conduct pressure testing of 2 products at the same time; (3) Water resources are wasted. The water consumption for pressure testing is large, and the water is discharged directly through the sewage pipe after the pressure test; (4) During the water pressure test, personnel are interspersed in the equipment area. The water pressure is high, and there is a certain safety hazard of water pressure impact on the operators. This utility model solves the above problems by integrating PLC intelligent control, multi-sensor interlocking and closed-loop water circulation system. Utility Model Content

[0003] The purpose of this invention is to provide an intelligent pressure testing control system and a complete pressure testing unit to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: an intelligent pressure testing control system complete pressure testing unit, including a test water tank, a pressure stabilizing tank, an underground water tank, a first centrifugal pump, and an intelligent control cabinet; the bottom of the test water tank is connected in series via pipelines to a shut-off valve, a reciprocating pump, a first anti-backflow check valve, a first electromagnetic control valve, a first pressure sensor, and a first pressure gauge;

[0005] The input end of the pressure stabilizing tank is connected to the electromagnetic control valve, and the output end of the pressure stabilizing tank is provided with a number of branches in parallel. Each branch is connected in series with a second anti-backflow check valve, a second electromagnetic control valve and a fourth pressure sensor, and is connected to multiple sets of detachable plate heat exchangers through the branch.

[0006] The underground water tank is connected in sequence to a soft water sedimentation tank, a sand tank, and a basket filter via pipelines. The output end of the basket filter is connected to the test water tank to form an external circulation system.

[0007] The input end of the first centrifugal pump is connected to the soft water sedimentation tank, and the output end of the centrifugal pump is connected to the test water tank through an electric regulating valve;

[0008] The intelligent control cabinet integrates a PLC controller and an HMI touch screen, and is connected to the first pressure sensor, the second pressure sensor, the third pressure sensor, the fourth pressure sensor, the first temperature sensor, the second temperature sensor, the first solenoid control valve, the second solenoid control valve, and the computer operation terminal for real-time control of test pressure, temperature, and water flow balance, and generates test pressure data reports.

[0009] Preferably, the pressure stabilizing tank integrates a safety valve and an electromagnetic pressure relief valve, and the top of the pressure stabilizing tank forms a constant pressure water supply circuit with the test water tank through a pipeline to ensure that the pressure inside the pressure stabilizing tank is constant.

[0010] Preferably, a second magnetic level gauge is installed between the underground water tank and the soft water sedimentation tank, a pressure sensor is installed between the soft water sedimentation tank and the sand tank, and a temperature sensor is installed between the sand tank and the basket sludge remover. Each sensor is interlocked with the intelligent control cabinet to achieve dynamic balance of liquid level and pressure.

[0011] Preferably, the intelligent control cabinet programs and sets multiple sets of pressure test parameters for the detachable plate heat exchanger through the PLC controller, and automatically controls the opening and closing sequence of the first electromagnetic control valve and the second electromagnetic control valve to simultaneously complete water injection, pressure increase, pressure holding and drainage operations.

[0012] Preferably, a second centrifugal pump is installed between the test water tank and the underground water tank. The input end of the test water tank is connected to the pressure stabilizing tank through a second shut-off valve, and the output end is fed back to the test water tank through a pipeline, forming a closed-loop water circulation system.

[0013] Preferably, the test water tank is equipped with a first magnetic level gauge.

[0014] The working process of this utility model is as follows:

[0015] (1) System initialization: Set the test pressure, holding time and other parameters of the detachable plate heat exchanger to be tested through the HMI touch screen of the intelligent control cabinet, start the PLC controller self-test program, and confirm that the status of each sensor and solenoid control valve is normal.

[0016] (2) Water injection and pressurization: The softened water in the test water tank is pressurized by a reciprocating pump and injected into the pressure stabilizing tank through the anti-backflow check valve and the electromagnetic control valve; the pressure stabilizing tank injects water into multiple heat exchangers simultaneously through a group of parallel branches including the anti-backflow check valve and the electromagnetic control valve; the centrifugal pump draws water from the soft water sedimentation tank, and after being filtered by a sand tank and finely filtered by a basket filter, it is replenished to the test water tank to form an external circulating water source.

[0017] (3) Pressure regulation and pressure holding: The PLC controller adjusts the opening of the electromagnetic control valve according to the real-time feedback of the pressure sensor, and controls the pressure increase rate of each branch to the preset value; after the target pressure is reached, the safety valve and electromagnetic pressure relief valve intervene to maintain the constant pressure state of the pressure stabilizing tank, and the system enters the pressure holding stage, and the temperature sensor monitors the water temperature change.

[0018] (4) Data recording and drainage: After the pressure holding is completed, the PLC automatically opens the electromagnetic pressure relief valve, and the pressure relief water is recycled through the underground water tank; the pressure curve, pressure holding time and other test data are automatically generated and archived by the computer operation terminal, and at the same time, the centrifugal pump is triggered to return the drainage to the test water tank for recycling.

[0019] The beneficial effects of this utility model are as follows:

[0020] (1) This utility model realizes the pressure testing of different models and specifications of the entire series of detachable plate heat exchangers, and performs pressure testing of multiple products at the same time, which shortens the product manufacturing cycle and increases the pressure testing efficiency to at least 8 times that of the original manual pressure testing equipment, greatly improving work efficiency and saving working time.

[0021] (2) In this utility model, the local control cabinet touch operating system and computer operation terminal can both preset the test pressure data values ​​of the series products. After setting the product series pressure values, the product test process can be fully automated and precisely controlled, reducing the manpower input for test pressure, reducing labor intensity, and saving 4 people for pressure injection and water injection operations.

[0022] (3) In this utility model, the computer operation terminal and the intelligent control cabinet can be arbitrarily set and modified to perform overall step-by-step pressure testing on the product to be pressure tested. The equipment automatically starts up and has self-testing and automatic pressure holding functions. It can realize arbitrary parameter settings of the touch system, automatic analysis of test pressure data, automatic recording of test pressure report, and collection and storage of test pressure data. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the system structure of this utility model;

[0024] In the diagram: 1-First magnetic level gauge, 2-Test water tank, 3-Basket-type filter, 4-Sand tank, 5-Magnetic level gauge, 6-Stop valve, 7-Reciprocating pump, 8-First anti-backflow check valve, 9-First electromagnetic control valve, 10-First pressure sensor, 11-First pressure gauge, 12-Electromagnetic pressure relief valve, 13-Soft water sedimentation tank, 14-First temperature sensor, 15-Second pressure sensor, 16-First centrifugal pump, 17-Electric regulating valve, 1 8-Second magnetic level gauge, 19-Underground water tank, 20-First shut-off valve, 21-Safety valve, 22-Pressure stabilizing tank, 23-Second temperature sensor, 24-Second shut-off valve, 25-Third pressure sensor, 26-Second pressure gauge, 27-Second centrifugal pump, 28-Second backflow prevention check valve, 29-Second electromagnetic control valve, 30-Fourth pressure sensor, 52-Detachable plate heat exchanger, 60-Computer operation terminal, 61-Intelligent control cabinet. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings.

[0026] like Figure 1 The intelligent pressure testing control system shown includes a complete pressure testing unit comprising a test water tank 2, a pressure stabilizing tank 22, an underground water tank 19, a first centrifugal pump 16, and an intelligent control cabinet 61. The bottom of the test water tank 2 is connected in series via pipelines to a shut-off valve 6, a reciprocating pump 7, a first anti-backflow check valve 8, a first electromagnetic control valve 9, a first pressure sensor 10, and a first pressure gauge 11. The input end of the pressure stabilizing tank 22 is connected to the first electromagnetic control valve 9, and the output end of the pressure stabilizing tank 22 is provided with several parallel branches. Each branch is connected in series with a second anti-backflow check valve 28, a second electromagnetic control valve 29, and a fourth pressure sensor 30, and is connected to multiple sets of detachable plate heat exchangers 52 via the branch. The underground water tank 19 is connected in series via pipelines to a soft water sedimentation tank. The system includes a tank 13, a sand tank 4, and a basket strainer 3. The output of the basket strainer 3 is connected to the test water tank 2 to form an external circulation system. The input of the first centrifugal pump 16 is connected to the soft water sedimentation tank 13, and the output of the first centrifugal pump 16 is connected to the test water tank 2 through an electric regulating valve 17. The intelligent control cabinet 61 integrates a PLC controller and an HMI touch screen, and is connected to the first pressure sensor 10, the second pressure sensor 15, the third pressure sensor 25, the fourth pressure sensor 30, the first temperature sensor 14, the second temperature sensor 23, the first electromagnetic control valve 9, the second electromagnetic control valve 29, and the computer operation terminal 60 for real-time control of test pressure, temperature, and water flow balance, and generates test pressure data reports.

[0027] The pressure stabilizing tank 22 integrates a safety valve 21 and an electromagnetic pressure relief valve 12. The top of the pressure stabilizing tank 22 forms a constant pressure water supply circuit with the test water tank 2 through a pipeline, ensuring that the pressure inside the pressure stabilizing tank 22 is constant.

[0028] A second magnetic level gauge 18 is installed between the underground water tank 19 and the soft water sedimentation tank 13. A second pressure sensor 15 is installed between the soft water sedimentation tank 13 and the sand tank 4. A temperature sensor 14 is installed between the sand tank 4 and the basket filter 3. Each sensor is interlocked with the intelligent control cabinet 61 to achieve dynamic balance of liquid level and pressure.

[0029] The intelligent control cabinet 61 sets the test parameters of multiple sets of detachable plate heat exchangers 52 through the PLC controller, and automatically controls the opening and closing sequence of the first electromagnetic control valve 9 and the second electromagnetic control valve 29 to simultaneously complete the water injection, pressure increase, pressure holding and drainage operations.

[0030] A second centrifugal pump 27 is installed between the test water tank 2 and the underground water tank 19. The input end of the test water tank 2 is connected to the pressure stabilizing tank 22 through the second shut-off valve 24, and the output end is connected to the test water tank 2 through a pipeline to return softened water to the test water tank 2, forming a closed-loop water circulation system. At the same time, the test water tank 2 is equipped with a first magnetic float level gauge 1.

[0031] The working process of this utility model is as follows:

[0032] (1) System initialization: Set the test pressure, holding time and other parameters of the detachable plate heat exchanger 52 to be tested through the HMI touch screen of the intelligent control cabinet 61, start the PLC controller self-test program, and confirm that the status of each sensor and solenoid control valve is normal.

[0033] (2) Water injection and pressurization: The softened water in the test water tank 2 is pressurized by the reciprocating pump 7 and injected into the pressure stabilizing tank 22 through the first anti-backflow check valve 8 and the first electromagnetic control valve 9; the pressure stabilizing tank 22 injects water into multiple heat exchangers 52 simultaneously through 8 sets of parallel branches including the second anti-backflow check valve 28 and the second electromagnetic control valve 29; the first centrifugal pump 16 draws water from the soft water sedimentation tank 13, filters it through the sand tank 4 and finely filters it through the basket filter 3, and then replenishes it to the test water tank 2 to form an external circulating water source.

[0034] (3) Pressure regulation and pressure holding: The PLC controller adjusts the opening of the second electromagnetic control valve 29 according to the real-time feedback of the fourth pressure sensor 30, and controls the pressure increase rate of each branch to the preset value; after the target pressure is reached, the safety valve 21 and the electromagnetic pressure relief valve 12 intervene to maintain the constant pressure state of the pressure stabilizing tank 22, and the system enters the pressure holding stage. The temperature sensor 23 monitors the water temperature change.

[0035] (4) Data recording and drainage: After the pressure holding is completed, the PLC automatically opens the electromagnetic pressure relief valve 12, and the pressure relief water is recovered through the underground water tank 19; the pressure curve, pressure holding time, etc. of the test data are automatically generated and archived by the computer operation terminal 60, and at the same time, the second centrifugal pump 27 is triggered to return the drainage to the test water tank 2 for recycling.

[0036] This invention utilizes an intelligent control system based on the automatic pressure testing principle of a pressure stabilizing tank, a multi-tank interlocking system, a centrifugal reciprocating pump, and a PLC integrated control system combining intelligent sensors, instruments, valve groups, and other components. This system enables water injection, pressure testing, pressure holding, and drainage of detachable plate heat exchangers under different operating conditions and for various models. The shell control system allows for adjustable, controllable, and recyclable water injection, pressure testing, pressure holding, and drainage of multiple heat exchangers. The intelligent control system, combined with remote-reading instruments and sensors, ensures reliable and stable operation of the entire pressure testing unit. The system allows for arbitrary settings and modifications to the computer operating terminal and intelligent control cabinet for gradual overall pressure testing. The equipment features automatic start-up, self-testing, and automatic pressure holding functions. It allows for arbitrary parameter settings via a touch-screen system, automatic analysis of pressure test data, automatic recording of pressure test reports, and automatic storage of pressure test data. The computer-based product pressure test database is automatically saved, resulting in energy-saving and environmentally friendly recycling of circulating water. This improvement enhances the automation and intelligence of the equipment, relieves operator stress during pressure testing, and significantly increases work efficiency.

[0037] The above are merely preferred embodiments of this utility model. It should be noted that, for those skilled in the art, based on the technical teachings provided by this utility model and as common knowledge in the field of pressure testing equipment technology, other equivalent modifications and improvements can be made, and these should also be considered within the scope of protection of this utility model.

Claims

1. An intelligent pressure test control system complete pressure unit, characterized in that, It includes test water tank (2), pressure tank (22), underground water tank (19), first centrifugal pump (16) and intelligent control cabinet (61); the bottom of the test water tank (2) is connected in series through pipeline with stop valve (6), reciprocating pump (7), first anti-backflow check valve (8), first electromagnetic control valve (9), first pressure sensor (10) and first pressure gauge (11); The input end of the pressure tank (22) is connected with the electromagnetic control valve (9), and a plurality of branch circuits are arranged in parallel at the output end of the pressure tank (22), each branch circuit is connected in series with second anti-backflow check valve (28), second electromagnetic control valve (29) and fourth pressure sensor (30) and is connected with a plurality of detachable plate heat exchangers (52) through the branch circuit; The underground water tank (19) is connected in series through pipeline with soft water precipitation tank (13), sand tank (4) and blue type dirt separator (3), the output end of the blue type dirt separator (3) is communicated with the test water tank (2), forming an external circulation system. The input end of the first centrifugal pump (16) is connected with the soft water precipitation tank (13), and the output end of the centrifugal pump (16) is communicated with the test water tank (2) through electric regulating valve (17). The intelligent control cabinet (61) is integrated with PLC controller and HMI touch screen and is signal connected with first pressure sensor (10), second pressure sensor (15), third pressure sensor (25), fourth pressure sensor (30), first temperature sensor (14), second temperature sensor (23), first electromagnetic control valve (9), second electromagnetic control valve (29) and computer operation end (60), for real-time regulation and control of pressure, temperature and water flow balance and generation of pressure test data report.

2. The intelligent pressure test control system complete pressure test unit of claim 1, wherein: The safety valve (21) and electromagnetic pressure relief valve (12) are integrated in the pressure tank (22), and a constant pressure water supply loop is formed between the top of the pressure tank (22) and the test water tank (2) through pipeline, so that the pressure in the pressure tank (22) is constant.

3. The intelligent pressure test control system complete pressure test unit of claim 1 or 2, characterized in that: The second magnetic flap liquid level meter (18) is arranged between the underground water tank (19) and the soft water precipitation tank (13), the pressure sensor (15) is arranged between the soft water precipitation tank (13) and the sand tank (4), the temperature sensor (14) is arranged between the sand tank (4) and the blue type dirt separator (3), and each sensor is interlocked with the intelligent control cabinet (61) to realize dynamic balance of liquid level and pressure.

4. The intelligent pressure testing control system complete pressure testing unit of claim 3, wherein: The intelligent control cabinet (61) sets pressure test parameters of the plurality of detachable plate heat exchangers (52) through programming of the PLC controller and automatically controls opening and closing time sequence of the first electromagnetic control valve (9) and the second electromagnetic control valve (29) to synchronously complete water injection, pressure rise, pressure maintenance and water discharge operations.

5. The intelligent pressure test control system complete pressure test unit of claim 4, wherein: The second centrifugal pump (27) is arranged between the test water tank (2) and the underground water tank (19), the input end of the test water tank (2) is connected with the pressure tank (22) through the second stop valve (24), and the output end of the test water tank (2) returns softened water to the test water tank (2) through pipeline, forming a closed loop water circulation system.

6. The intelligent pressure test control system complete pressure test unit of claim 5, wherein: The first magnetic flap liquid level meter (1) is arranged on the test water tank (2).

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