An online flange leak-off device

Abstract

The utility model discloses a kind of flange online leak removal devices, relate to pipeline online repair field, including fixed pressing plate, several bolt holes are opened in the fixed pressing plate, two the bolt holes are provided with end fixed component, top seal component is also provided on the fixed pressing plate, the top seal component includes the U-shaped slot between two end fixed components, the inside of the U-shaped slot is provided with pressure block, the pressure block can be moved along the thickness direction of fixed pressing plate, for straining the two sides of U-shaped slot, make U-shaped slot and flange sealing surface abut;The utility model is cooperated with expansion sleeve by expansion screw of end fixed component, the fixation of device and flange is quickly realized, without welding or wrapping to flange whole, adapt to different specifications flange, solve the problem that flange leak removal needs overall processing in prior art, time-consuming and laborious, reduce manpower and material resources cost, improve maintenance efficiency.

Description

Technical Field

[0001] This utility model belongs to the field of online pipeline repair, specifically an online flange leak elimination device. Background Technology

[0002] In power plants, petrochemical plants, energy transmission, and municipal water supply, flanges, as core components of pipeline connections, are prone to leakage during long-term operation due to issues such as wear of sealing surfaces, loose bolts, and media corrosion. Since most pipeline systems require continuous operation (such as chemical production pipelines and urban water supply networks) and cannot be shut down for maintenance, "online leak detection" has become a key requirement for solving flange leakage problems. However, existing online flange leak detection technologies have significant shortcomings in operational efficiency and adaptability, making it difficult to meet the need for rapid and low-cost repairs.

[0003] Existing online leak sealing solutions mainly fall into two categories: one is welded sealing, which requires welding a sealed cavity to the outside of the flange and then injecting sealant into the cavity. However, this method requires highly skilled welders, and the high temperature during welding can easily damage the flange body or pipeline coating, making it particularly unsuitable for flanges made of easily damaged materials such as stainless steel and non-ferrous metals. Furthermore, welding is time-consuming, and in cases of large leaks, temporary sealing is required, further extending the repair cycle. The other category is integral wrapping clamps, which require fitting the entire flange into a customized clamp and securing it with bolts to form a sealed cavity. However, these clamps must be custom-made according to flange specifications (diameter, sealing surface width), making them unsuitable for flanges of different sizes and exhibiting extremely poor versatility. Additionally, the integral clamps are large and heavy, making installation difficult in confined spaces (such as areas with dense piping), severely limiting operational flexibility. Utility Model Content

[0004] The purpose of this invention is to provide an online flange leak elimination device to solve the problems of existing online leak elimination technologies, such as complex operation, poor adaptability, easy damage to flanges during welding, low versatility of customized fixtures, and difficulty in meeting the needs for rapid and low-cost repair.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an online flange leak-proof device, including a fixed pressure plate, wherein the fixed pressure plate has a plurality of bolt holes, wherein two of the bolt holes are provided with end fixing components, and the fixed pressure plate is also provided with a top sealing component;

[0006] The top sealing assembly includes a U-shaped groove located between two end fixing assemblies. A pressure block is provided on the inner side of the U-shaped groove. The pressure block can move along the thickness direction of the fixed pressure plate to open the two sides of the U-shaped groove so that the U-shaped groove abuts against the flange sealing surface.

[0007] A glue injection tube is fixedly installed on the pressure block. The end of the glue injection tube slides through the U-shaped groove and the fixed pressure plate in sequence to inject sealant into the sealing chamber where the flange leakage point is located.

[0008] Preferably, the end fixing assembly includes an expansion screw disposed in the corresponding bolt hole, an expansion sleeve sleeved on the expansion screw, and the side wall of the expansion sleeve abutting against the two end faces of the U-shaped groove to limit the position of the U-shaped groove and enhance the stability of the top sealing assembly.

[0009] Preferably, one end of the expansion screw is machined with a conical frustum, and the other end is machined with an external thread and threaded to a nut. The outer wall of the expansion sleeve is provided with several axially open grooves for the expansion sleeve to radially expand and fit against the flange hole wall, thereby fixing the device to the flange.

[0010] Preferably, a long bolt is provided on the pressure block, and the end of the long bolt passes through the pressure block, the U-shaped groove, and the fixed pressure plate in sequence. The end of the long bolt is threaded with a nut, and the long bolt is used to drive the pressure block to move along the thickness direction of the fixed pressure plate.

[0011] Preferably, a spring washer is provided between the long bolt and the fixed pressure plate. The spring washer is used to prevent the long bolt from loosening during the pressurization process and to ensure the movement accuracy of the pressure block.

[0012] Preferably, the pressure block is a wedge-shaped block or a T-shaped block. The side of the T-shaped block is provided with a beveled surface. The beveled edge of the wedge-shaped block or the beveled surface of the T-shaped block is adapted to the inner bevel of the U-shaped groove to open the U-shaped groove.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] 1. This utility model uses the expansion screw and expansion sleeve of the end fixing component to quickly fix the device to the flange without the need for overall welding or wrapping of the flange. It is compatible with flanges of different specifications and solves the problem that flange leakage elimination in the prior art requires overall treatment, which is time-consuming and labor-intensive. It reduces manpower and material costs and improves maintenance efficiency.

[0015] 2. This utility model utilizes the U-shaped groove of the top sealing component in conjunction with the pressure block. The long bolt drives the pressure block to move, which opens the U-shaped groove and forms a closed chamber with the flange sealing surface, reducing sealant leakage and adapting to complex working conditions such as high pressure and high temperature. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this utility model. For those skilled in the art, other drawings can be obtained based on these drawings.

[0017] Figure 1 This is a first-view perspective three-dimensional structural diagram of an embodiment of the present utility model;

[0018] Figure 2 This is a second-view perspective three-dimensional structural diagram provided for an embodiment of the present utility model;

[0019] Figure 3 This is a three-dimensional structural diagram of a wedge-shaped block provided in an embodiment of the present invention.

[0020] Figure 4 This is a three-dimensional structural diagram of a T-shaped pressure block provided in an embodiment of the present invention.

[0021] In the picture:

[0022] 1. Fixed pressure plate; 2. End fixing assembly; 3. Expansion screw; 4. Expansion sleeve; 5. Top sealing assembly; 6. U-shaped groove; 7. Pressure block; 8. Long rod bolt; 9. Glue injection tube. Detailed Implementation

[0023] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0024] As attached Figure 1 To be continued Figure 4 As shown:

[0025] This utility model provides an online flange leak-proof device, including a fixed pressure plate 1. The surface of the fixed pressure plate 1 is hot-dip galvanized, with a zinc layer thickness ≥85μm and a salt spray corrosion resistance ≥1000 hours. It is rectangular, with a length of 150-300mm and a width of 80-120mm. It has three bolt holes, each with a diameter 1mm larger than the corresponding bolt. The distance between the two side holes matches the distance between the flange bolt holes (range 50-200mm), and the distance between the side holes and the top hole is 80-150mm. End fixing components 2 are installed in two of the bolt holes (side holes). A top sealing component 3 is also provided on the fixed pressure plate 1. The top sealing component 3 includes a U-shaped groove 301 located between the two end fixing components 2. The U-shaped groove 301 is made of 304 stainless steel sheet, bent to a thickness of 5mm, and is U-shaped. The opening width matches the width of the flange sealing surface (10-20mm), and the length is 120-25mm. 0mm (covering the leakage point and 20mm area on both sides), height 30-50mm, 2mm rubber sealing gasket pasted on the inner side, V-shaped groove (depth 1mm, width 2mm) machined on the surface of the sealing gasket, circular through holes opened on both end faces (hole diameter 0.5mm larger than the outer diameter of expansion sleeve 202), reinforcing ring (thickness 3mm, diameter 20-30mm) welded circumferentially to the through holes, pressure block 302 is provided on the inner side of the U-shaped groove 301, pressure block 302 can move along the thickness direction of fixed pressure plate 1, used to open the two sides of the U-shaped groove 301, so that the U-shaped groove 301 abuts against the flange sealing surface; glue injection tube 5 is fixedly installed on the pressure block 302, glue injection tube 5 is made of 304 stainless steel pipe, one end is machined with external thread and connected to sealing cap, the end of glue injection tube 5 slides through the U-shaped groove 301 and fixed pressure plate 1 in sequence, used to inject sealant into the sealing chamber where the flange leakage point is located.

[0026] During operation, firstly, identify the leak point and select two suitable expansion bolts 201. Insert them radially into the flange gaps on both sides of the leak point, and tighten the nuts to expand and fix the expansion sleeve 202. If necessary, spot welding can be used for reinforcement. Then, install the pressure block 302 with the long bolt 4 into the U-shaped groove 301. The assembly is vertically placed between the two expansion bolts 201. Install the fixing plate 4 and align and initially tighten each bolt. Subsequently, the driving structure moves the pressure block 302 along the thickness direction of the fixing plate 1. The U-shaped groove 301 is opened on both sides to allow it to fit tightly against the flange sealing surface, forming a sealed chamber. Finally, the glue gun is connected to the external thread end of the glue injection tube 5 to inject sealant into the sealed chamber. The sealant fills the chamber and seals the leak point. The sealing cap is tightened to prevent the sealant from flowing back, completing the online leak elimination of the flange. Through this process, there is no need to weld or wrap the entire flange, which can quickly achieve online leak elimination of the flange, adapt to different flange specifications, reduce manpower and material costs, and improve maintenance efficiency.

[0027] As attached Figure 1 To be continued Figure 4 As shown, in one embodiment of this utility model, the end fixing component 2 includes an expansion screw 201 disposed in a corresponding bolt hole. One end of the expansion screw 201 is machined with a conical frustum, and the other end is machined with an external thread and threaded with a nut. An annular groove is opened in the middle. An expansion sleeve 202 is sleeved on the expansion screw 201. The expansion sleeve 202 is made of seamless steel pipe. The inner wall is machined with a conical surface that matches the conical frustum of the expansion screw 201. An annular protrusion is provided in the middle of the outer wall. The outer wall is also provided with 3 axial opening grooves. The side wall of the expansion sleeve 202 abuts against the two end faces of the U-shaped groove 301 to limit the position of the U-shaped groove 301 and enhance the stability of the top sealing component 3.

[0028] During operation, the operator first inserts the expansion sleeve 202 onto the tapered end of the expansion screw 201, passing them together through the waist hole of the fixing plate 1, so that the side wall of the expansion sleeve 202 abuts against the two end faces of the U-shaped groove 301. Then, the operator uses a wrench to rotate the nut at the threaded end of the expansion screw 201 clockwise, causing the expansion screw 201 to rotate. Its tapered tip presses against the inner wall of the expansion sleeve 202, causing the expansion sleeve 202 to expand radially along the axial opening groove (expansion amount 0.5-1mm), tightly fitting against the flange plane. At the same time, the annular protrusion on the outer wall of the expansion sleeve 202 embeds into the annular groove of the expansion screw 201, preventing the expansion sleeve 202 from falling off. Through this operation, the device and flange can be reliably fixed quickly. The side wall of the expansion sleeve 202 abutting against the U-shaped groove 301 can also limit the position of the U-shaped groove 301, preventing the U-shaped groove 301 from shifting during pressurization or glue injection, enhancing the stability of the top sealing assembly 3, ensuring the sealing performance of the sealing chamber, and thus ensuring the leak-proof effect.

[0029] As attached Figure 1 To be continued Figure 4 As shown, in one embodiment of this utility model, a long rod bolt 4 is provided on the pressure block 302. The upper end of the long rod bolt 4 is provided with a hexagonal head. The end of the long rod bolt 4 passes through the pressure block 302, the U-shaped groove 301, and the fixed pressure plate 1 (passing through the top hole of the fixed pressure plate 1) in sequence. The end of the long rod bolt 4 is threadedly connected with a nut (hexagonal nut, which matches the thread of the long rod bolt 4). The long rod bolt 4 is used to drive the pressure block 302 to move along the thickness direction of the fixed pressure plate 1.

[0030] During operation, the worker first inserts the long bolt 4 from top to bottom through the top hole of the fixed pressure plate 1, passing it sequentially through the threaded holes of the U-shaped groove 301 and the pressure block 302, so that the end of the long bolt 4 extends out of the pressure block 302. Then, a nut is threaded onto the end of the long bolt 4 and initially tightened. Next, the nut of the long bolt 4 is rotated clockwise with a wrench. The hexagonal head of the long bolt 4 restricts its axial movement, allowing the pressure block 302 to move along the thickness direction of the fixed pressure plate 1. During the movement of the pressure block 302, it presses against the inner side of the U-shaped groove 301. This forces the two sides of the U-shaped groove 301 to spread outwards; the number of rotations of the nut is adjusted as needed to control the moving distance of the pressure block 302, thereby controlling the degree of opening of the U-shaped groove 301, so that the U-shaped groove 301 and the flange sealing surface achieve a suitable fit; the pressure block 302 is driven to move by the long bolt 4, the transmission is stable and reliable, and the moving distance of the pressure block 302 can be precisely controlled, thereby precisely controlling the degree of opening of the U-shaped groove 301, ensuring that the U-shaped groove 301 and the flange sealing surface fit tightly together to form an effective sealing chamber.

[0031] As attached Figure 1 To be continued Figure 4 As shown, in one embodiment of this utility model, a spring washer (material 65Mn, thickness 2mm, surface galvanized for rust prevention) is provided between the long rod bolt 4 and the fixed pressure plate 1. The spring washer is used to prevent the long rod bolt 4 from loosening during the pressurization process and to ensure the moving accuracy of the pressure block 302.

[0032] During operation, the operator first places a spring washer on the long bolt 4, positioning it between the head of the bolt 4 and the top hole of the fixed pressure plate 1. Then, following the same steps, the operator installs the long bolt 4 and drives the pressure block 302 to move. During pressurization, the long bolt 4 is subjected to axial force, causing the spring washer to undergo elastic deformation and generate a reverse elastic force. This maintains a certain preload between the threads of the long bolt 4 and between the bolt head and the fixed pressure plate 1. Even if vibration or slight force changes occur during pressurization, the elastic force of the spring washer can offset some of the loosening tendency, preventing the long bolt 4 from loosening. By setting the spring washer, the long bolt 4 is prevented from loosening during pressurization, ensuring that the pressure block 302 moves according to the expected trajectory and distance, guaranteeing the movement accuracy of the pressure block 302. This, in turn, ensures that the U-shaped groove 301 can stably open and maintain good contact with the flange sealing surface, ensuring the sealing performance of the sealing chamber and improving the stability of the leak-proof effect.

[0033] In one embodiment of this utility model, the pressure block 302 is selected as a wedge-shaped block or a T-shaped block, as shown in the attached figure. Figure 3 As shown, the inclined side of the wedge block is adapted to the inner inclined surface of the U-shaped groove 301 (inclination 1:10), the surface is polished, and an axial threaded hole is opened in the middle to mate with the long bolt 4; as shown in the attached figure. Figure 4 As shown, the side of the T-block is provided with a beveled surface (bevel angle 1:8), the surface is polished, and the center is also provided with an axial threaded hole that mates with the long rod bolt 4. The beveled edge of the wedge block or the beveled surface of the T-block is adapted to the inner bevel of the U-shaped groove 301 to open the U-shaped groove 301.

[0034] During operation, if a wedge block is used as the pressure block 302, the operator first places the wedge block inside the U-shaped groove 301, ensuring the inclined edge of the wedge block aligns with the inner inclined surface of the U-shaped groove 301, and the threaded hole of the wedge block aligns with the top hole of the fixed pressure plate 1. Next, the long bolt 4 is installed, and the wedge block is driven to move along the thickness direction of the fixed pressure plate 1. The inclined edge of the wedge block presses against the inner inclined surface of the U-shaped groove 301. Due to the 1:10 inclination, when the wedge block rises 1mm, the two sides of the U-shaped groove 301 can be opened by 0.1mm, precisely opening the U-shaped groove 301. If a T-shaped block is used as the pressure block 302, the operator places the T-shaped block inside the U-shaped groove 301, ensuring the inclined surface of the T-shaped block aligns with the U-shaped groove. The inner bevel of 301 fits together, the threaded hole of the T-block aligns with the top hole of the fixed pressure plate 1, and the T-block is driven to move by the long bolt 4. The beveled surface of the T-block presses against the inner bevel of the U-shaped groove 301. Due to the 1:8 bevel and large lateral contact area, the U-shaped groove 301 can be stably opened, which is suitable for scenarios with large flange sealing surface width errors. By selecting different types of pressure blocks 302, it can be adapted to different flange sealing surface width errors and leakage pressure scenarios. The wedge block has high adjustment accuracy and is suitable for scenarios with small errors, while the T-block is subjected to uniform force and is suitable for scenarios with large errors. This improves the versatility and adaptability of the device and ensures that the U-shaped groove 301 can be effectively opened under different working conditions to form a reliable sealing chamber.

[0035] When a leak occurs at a specific point on the flange sealing assembly, the operator should use this device to perform online sealing by following these steps:

[0036] Working principle:

[0037] Step 1: After confirming the location of the leak, select two suitable expansion bolts 201. Insert these two expansion bolts 201 parallel to the radial direction of the leak point (or along the radial direction of the flange) into the gaps between the two flanges on both sides of the leak point, ensuring that the conical frustum end face of the bolt firmly abuts against the outer annular surface of the flange sealing surface. Adjust the distance between the two expansion bolts 201 to match the length of the U-shaped groove 301. Use a wrench to tighten the nuts on the expansion bolts 201, causing the expansion sleeve 202 fitted on its outer side to expand and securely connect to the flange assembly. If the connection is found to be insufficiently secure during this process (e.g., due to excessive flange clearance), spot welding can be used to further fix the expansion bolts 201 to the flange to ensure absolute reliability throughout the entire operation.

[0038] Step 2: Install the pressure block 302 with the long bolt 4 into the U-shaped groove 301 to form an assembly. Then place the assembly vertically so that it is embedded between the two fixed expansion bolts 201 and sits on the flange leakage point.

[0039] Step 3: Align the three screw holes on the fixed pressure plate 1 (two for the expansion screws 201 and one for the long bolt 4 of the pressure block 302) with the corresponding screw holes. First, install the nuts on the tops of the two expansion screws 201 and tighten them initially to press and fix the fixed pressure plate 1, ensuring the stability of the entire device structure.

[0040] Step 4: Use a wrench to tighten the nut at the top of the long bolt 4 of the pressure block 302. Since the long bolt 4 is threadedly connected to the pressure block 302 and its upward movement is constrained by the fixed pressure plate 1, tightening the nut will cause the pressure block 302 to rise vertically upwards. As the pressure block 302 rises, its two inclined surfaces interact with the inner inclined surface of the U-shaped groove 301, forcing the bottom of the U-shaped groove 301 to expand outwards (towards the flange end face) and press tightly, thereby forming a closed sealing chamber between the U-shaped groove 301 and the flange sealing surface. When the pressure block 302 can no longer rise, it indicates that the chamber has been formed and sealed.

[0041] Step 5: Securely connect the outlet of the glue gun to the pre-installed glue injection tube 5 on the pressure block 302. Start the glue gun and inject the sealant into the formed sealed cavity under appropriate pressure (determined according to the leakage medium and pressure conditions on site). The sealant will fill the entire cavity and penetrate into the leakage defect until the leakage is observed to be completely eliminated.

[0042] Step 6: After the sealant injection is completed, immediately tighten the locking cap on the sealant injection tube 5 to seal the tube, prevent sealant backflow, and maintain pressure within the chamber. Once the sealant has fully cured, the leak detection is complete.

[0043] The foregoing description only illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. An online flange leak-proof device, characterized in that: It includes a fixed pressure plate (1), which has a plurality of bolt holes, two of which are provided with end fixing components (2), and the fixed pressure plate (1) is also provided with a top sealing component (3); The top sealing assembly (3) includes a U-shaped groove (301) located between two end fixing assemblies (2). A pressure block (302) is provided on the inner side of the U-shaped groove (301). The pressure block (302) can move along the thickness direction of the fixing plate (1) to open up the two sides of the U-shaped groove (301) so that the U-shaped groove (301) abuts against the flange sealing surface. The pressure block (302) is fixedly provided with a glue injection tube (5). The end of the glue injection tube (5) slides through the U-shaped groove (301) and the fixed pressure plate (1) in sequence to inject sealant into the sealing chamber where the flange leakage point is located.

2. The flange online leak-proof device according to claim 1, characterized in that: The end fixing assembly (2) includes an expansion screw (201) disposed in the corresponding bolt hole. An expansion sleeve (202) is sleeved on the expansion screw (201). The side wall of the expansion sleeve (202) abuts against the two end faces of the U-shaped groove (301) to limit the position of the U-shaped groove (301) and enhance the stability of the top sealing assembly (3).

3. The flange online leak-proof device according to claim 2, characterized in that: One end of the expansion screw (201) is machined with a conical frustum, and the other end is machined with an external thread and threaded with a nut. The outer wall of the expansion sleeve (202) is provided with several axial opening grooves for the expansion sleeve (202) to radially expand and fit against the flange hole wall, thereby fixing the device to the flange.

4. The flange online leak-proof device according to claim 1, characterized in that: The pressure block (302) is provided with a long rod bolt (4), the end of which passes through the pressure block (302), the U-shaped groove (301), and the fixed pressure plate (1) in sequence, and the end of the long rod bolt (4) is threaded with a nut. The long rod bolt (4) is used to drive the pressure block (302) to move along the thickness direction of the fixed pressure plate (1).

5. The flange online leak-proof device according to claim 4, characterized in that: A spring washer is provided between the long rod bolt (4) and the fixed pressure plate (1). The spring washer is used to prevent the long rod bolt (4) from loosening during the pressurization process and to ensure the moving accuracy of the pressure block (302).

6. The flange online leak-proof device according to claim 1, characterized in that: The pressure block (302) is selected as a wedge block or a T-shaped block. The side of the T-shaped block is provided with a beveled surface. The beveled edge of the wedge block or the beveled surface of the T-shaped block is adapted to the inner bevel of the U-shaped slot (301) to open the U-shaped slot (301).

Images