Sensors for detecting scour damage and control valves using them

Abstract

This utility model relates to the field of control valve testing, specifically to a sensor for detecting damage such as erosion, cavitation, and corrosion to internal components of a high-parameter control valve, and a control valve using this sensor. The sensor includes a circuit layer clamped between two components being tested; each component has a channel, and the circuit layer is annular, clamped between the end faces of the two components perpendicular to the channel axis; the circuit layer has at least one detection section, each detection section including multiple resistor components spaced apart from the erosion surface near the component to the side away from the erosion surface; each resistor component includes at least two resistors arranged along the contour of a cross-section parallel to the circuit layer along the erosion surface; in each detection section, the resistors of each resistor component, aligned from the side near the erosion surface to the side away from the erosion surface, are connected in parallel. This utility model can accurately achieve online detection of physical damage to key components caused by cavitation, erosion, and corrosion.

Description

Technical Field

[0001] This utility model relates to the field of valve detection, specifically to a sensor for detecting scour damage and a control valve using the same. Background Technology

[0002] In the field of automation control in process industries such as chemical and power plants, control valves, as the core actuators of fluid control systems, directly affect the safety and economy of the entire production process due to their performance stability and reliability. Especially in high-risk industries such as nuclear power and coal chemical industry, the failure of control valves can lead to catastrophic consequences.

[0003] Therefore, important, critical, and vulnerable control valves, such as high-risk control valves used in important locations like nuclear power plants and high-scouring control valves used in coal chemical enterprises, require real-time monitoring. In some cases, high-level design using digital twins and deep learning is necessary to understand the damage to important and critical internal valve components caused by corrosion, cavitation, and scouring.

[0004] In existing technologies, monitoring of control valves mainly relies on periodic offline testing and preventative maintenance strategies. For example, non-destructive testing methods such as ultrasonic thickness measurement and penetrant testing are used to assess valve body wall thinning, or empirical models based on parameters such as operating time and opening changes are used to predict remaining lifespan. However, offline testing suffers from insufficient timeliness, cumbersome testing methods, and low reliability, while empirical models have limitations in accurately quantifying complex operating conditions and have limited accuracy.

[0005] Therefore, there is an urgent need to design a sensor that can detect the scouring damage of control valves online, in order to overcome the shortcomings of traditional monitoring methods. Summary of the Invention

[0006] The technical problem to be solved by this utility model is to overcome the defects of the prior art and provide a sensor for detecting erosion damage, which can accurately realize online detection of physical damage to key components caused by corrosion, cavitation, erosion and other factors.

[0007] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows: a sensor for detecting erosion damage, comprising a circuit layer clamped between two tested components, wherein the circuit layer has at least one detection part; wherein... Each detection unit includes multiple resistor components spaced apart from the scouring surface near the test piece to the surface away from the scouring surface, with each resistor component connected in parallel.

[0008] Furthermore, to improve the reliability of the detection, each resistor assembly includes at least two resistors arranged along the profile of a cross section parallel to the circuit layer on the scouring surface; In each detection section, the resistors of each resistor assembly are connected in parallel from the closest to the scouring surface to the furthest from the scouring surface.

[0009] Furthermore, to facilitate electrical connection between the sensor and other components, the circuit layer is provided with lead wire trays at a position away from the scouring surface, each corresponding to a parallel lead wire of the resistor assembly, and each parallel lead wire is electrically connected to the corresponding lead wire tray.

[0010] Furthermore, the tested component is provided with a channel, and the circuit layer is annular and is sandwiched between the end faces of the two tested components that are perpendicular to the channel axis.

[0011] Furthermore, in order to determine the direction of the erosion damage, at least two detection units are provided, distributed circumferentially along the circuit layer.

[0012] Furthermore, the circuit layer is a thick-film circuit; or the circuit layer is a metal-based embedded circuit fabricated on the end face of one of the tested devices.

[0013] Furthermore, the material of the tested component is metal.

[0014] This utility model also relates to a control valve, including the aforementioned sensor for detecting scouring damage.

[0015] Furthermore, a connector is mounted on the valve body of the control valve, the connector comprising a base, an insulator, and multiple pins; wherein, The base is inserted into the electrical channel of the valve body, with one end face abutting against the stepped surface of the electrical channel and the other end face abutting against the electrical end cap that is pressed against it and connected to the valve body; The substrate is provided with a through hole, and the insulator is sealed and inserted into the through hole; Multiple pins are spaced apart and embedded in the insulator, with their axial direction parallel to the axial direction of the insulator, and both ends extending beyond the insulator. The end extending inward from the insulator is electrically connected to the erosion damage detection sensor.

[0016] Furthermore, the valve is a black water angle valve, a sleeve valve, a single-seat valve, a ball valve, or a nuclear power valve.

[0017] By adopting the above technical solution, this utility model can determine the wear condition of the tested part by measuring the resistance value change of each detection part online, and realize the online detection of the erosion damage of the tested part. It has high real-time performance, high detection accuracy, and is easy to implement with low implementation cost. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the sensor for detecting scour damage according to this utility model; Figure 2 for Figure 1 Enlarged view of part A; Figure 3 This is an equivalent circuit diagram of a detection unit according to the present invention; Figure 4 This is a schematic diagram of the structure of the valve core of a valve for applying the scouring damage detection sensor of this utility model; Figure 5 This is a schematic diagram showing the result of applying the scouring damage detection sensor of this utility model to the fluid channel forming component of a black water angle valve; Figure 6 for Figure 5 Enlarged view of part B; Figure 7 This is a schematic diagram of the structure of the scouring damage detection sensor of this utility model applied to the valve seat of a sleeve valve; Figure 8 for Figure 7 Enlarged view of part C; Figure 9 This is a schematic diagram of the structure of the scour damage detection sensor of this utility model applied to the valve seat of a single-seat valve; In the picture: 1. Component under test; 2. Circuit layer; 3. Detection unit; 31. Resistor assembly; 311. Resistor; 32. Parallel lead wire; 33. Lead wire reel; 4. Channel; Valve body; 101, electrical channel; 20, connector; 201, base; 2011, through hole; 202, insulator; 203, pin; 30, valve core; 40, electrical end cap; 100. Black water angle valve; 1001. Upper sleeve; 1002. Middle sleeve; 1003. Valve seat body; 1004. Venturi sleeve; 200. Sleeve valve; 2001. Upper valve seat; 2002. Lower valve seat; 300, Single-seat valve; 3001, First valve seat; 3002, Second valve seat. Detailed Implementation

[0019] To make the contents of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0020] like Figures 1 to 9 As shown, a sensor for detecting erosion damage includes a circuit layer 2 sandwiched between two objects 1 to be detected, the circuit layer 2 having at least one detection unit 3; wherein, Each detection unit 3 includes a plurality of resistor components 31 spaced apart from the scouring surface near the test piece 1 to the distance away from the scouring surface, and the plurality of resistor components 31 are connected in parallel. Each resistor component 31 may have one resistor 311, two resistors 311, three resistors 311, etc.

[0021] Specifically, by measuring the resistance change of each detection unit 3 online, the wear condition of the tested part 1 can be determined, realizing online detection of the erosion damage of the tested part 1. It has high real-time performance, high detection accuracy, and is easy to implement with low implementation cost.

[0022] In this embodiment, preferably, as follows: Figure 1 , Figure 2 and Figure 3 As shown, each resistor assembly 31 includes at least two resistors 311 arranged along the contour of a cross section parallel to the circuit layer 2 on the scouring surface; in each detection unit 3, the resistors 311 of each resistor assembly 31 that are aligned from the closest to the scouring surface to the furthest from the scouring surface are connected in parallel. That is, in each detection unit 3, the number of resistors 311 in each resistor assembly 31 is equal, and the resistors 311 that are aligned with each other in the wear depth direction are connected in parallel.

[0023] Specifically, the resistor assembly 31 is configured to include at least two resistors 311 arranged along the contour of a cross-section parallel to the circuit layer on the erosion surface, and the resistors 311 aligned with each other in parallel in the wear depth direction. This is to improve the reliability of monitoring: on the one hand, if a circuit formed by parallel resistors 311 aligned with each other in the radial direction fails to detect, there is another set, or even two or three sets, that can be used for comparison; on the other hand, because even a erosion as small as a pinhead will cause a resistor 311 to open circuit, if two or even three circuits are open, it indicates that the erosion area is large. Furthermore, each resistor assembly 31 includes at least two resistors 311 arranged along the direction of the erosion surface, which also expands the detection range.

[0024] In this embodiment, preferably, as follows: Figure 1 and Figure 2 As shown, in the same resistor assembly 31, the close ends of any two adjacent resistors 311 are connected.

[0025] In this embodiment, preferably, as follows: Figure 1 and Figure 2 As shown, circuit layer 2 has lead-out trays 33 located away from the scouring surface, each corresponding to a parallel lead-out wire 32 of the resistor assembly 31. Each parallel lead-out wire 32 is electrically connected to its corresponding lead-out tray 33. This facilitates the connection of the sensor.

[0026] In this embodiment, the scouring surface of the tested component 1 can be a plane, an inner circumferential surface, or an outer circumferential surface. When it is a plane, the outline of the cross-section of the scouring surface parallel to the circuit layer 2 is a straight line. When it is an inner or outer circumferential surface, the outline of the cross-section of the scouring surface parallel to the circuit layer 2 is an arc line on a circle.

[0027] When the scouring surface of the tested component 1 is an inner or outer circumferential surface, the tested component 1 is provided with a channel 4, and the circuit layer 2 is annular and sandwiched between the end faces of the two tested components 1. Wherein, when the scouring surface is an inner circumferential surface, the channel 4 is the flow channel of the tested component 1, and when the scouring surface is an outer circumferential surface, the channel 4 is the wiring path for connecting the sensor to external devices.

[0028] by Figure 1 and Figure 2 Taking the sensor shown as an example, the detected component 1 uses channel 4 as the flow channel, and the scouring surface of the detected component 1 is the inner circumferential surface of the detected component 1. At least two detection units 3 are provided, distributed circumferentially along the circuit layer 2 (preferably evenly distributed circumferentially), and can detect multiple positions of the scouring surface in the circumferential direction. Each resistor assembly 31 is designed with a radial spacing of L in the circuit layer 2. The spacing L is determined according to the required detection accuracy and can be, but is not limited to, 0.2 mm. The number of layers from the inside out can be determined according to the required scouring thickness. Each circuit assembly 31 includes at least two resistors 311 arranged circumferentially along the circuit layer 2. The resistors 311 aligned radially in each circuit assembly 31 are connected in parallel, and each parallel lead 32 is connected to a corresponding lead disk 33 located in the circuit layer 2 away from the scouring surface (i.e., at the outer edge of the circuit layer 2). Figure 1 In the sensor, there are four detection units 3, each detection unit 3 is provided with eight layers of circuit components 31, each circuit component 31 has two resistors 311 (the two resistors 311 are connected at their close ends), and there are 12 corresponding lead wire trays 33. Each parallel lead wire 32 is routed along the circuit layer 12 near the outer ring to avoid the parallel lead wire 32 being broken due to sensor erosion damage.

[0029] It is important to note that Figure 1 and Figure 2 The resistor 311 shown is wavy. Resistor 311 can also be an arc that bends along the circumference of the circle in which it is located, depending on the required resistance value and the size of the entire resistor assembly 31 in the circumferential direction of the circuit layer 2.

[0030] To understand more intuitively Figure 1 The circuit in the detection unit 3 of the sensor, Figure 1 One of the sensor's detection units 3 can be equivalent to... Figure 3In the circuit, resistors R11 and R21 form the first layer (closest to the scouring surface, i.e., the inner circle side) of resistor assembly 31, resistors R12 and R22 form the second layer of resistor assembly 31, resistors R13 and R23 form the third layer of resistor assembly 31, and so on, resistors R18 and R28 form the eighth layer of resistor assembly 31 (farthest from the scouring surface). Resistors R11, R12, R13...R18 are aligned radially in circuit layer 2 and connected in parallel with each other. Resistors R21, R22, R23...R28 are also aligned radially in circuit layer 2 and connected in parallel with each other. Each detection unit 3 has three parallel leads 32, which are connected to three lead disks 33, namely a, b, and c. Resistors R11, R21, R12, R22, etc., can be made from 10Ω to 1MΩ, and the values ​​of each resistor can be equal or unequal.

[0031] If the surface of the tested component 1 is damaged by erosion during operation, the resistance value between a and b, or between b and c, will change. In addition, the distance between the resistor components 31 of each layer can be used to determine the extent of erosion damage to the tested component 1 based on the change in resistance value. The direction of the erosion damage can also be determined based on the location of the change in resistance value.

[0032] In this embodiment, the circuit layer 2 can be formed in various ways, such as a thick film circuit or a metal-based embedded circuit processed on the end face of one of the tested components 1.

[0033] When circuit layer 2 is a thick-film circuit, the fabrication method may include: (1) Circuit board substrate: Alumina (Al2O3) ceramic, zirconia ceramic (ZrO2) and toughened alumina ceramic (Al2O3+ZrO2) can be used as insulating layers, with a breakdown strength ≥20KV / mm, and can work stably for a long time at temperatures above 450℃ (600℃ for inert media). (2) Resistors 311: can be printed using sputtering, etching and other processes such as RuO2 and TaN. The resistivity of RuO2 is 1KΩ / cm~10KΩ / cm and the resistivity of TaN is 0.2Ω / cm. The resistance change rate of both is less than 2% in the aging test at 300℃. (3) Conductors and coils: can be made by sputtering or etching with titanium, copper, nickel, or even gold and silver materials, with adhesion ≥15MPa and long-term oxidation resistance ≥350℃; (4) Protective layer: The outermost layer is deposited with ALD and coated with Al2O3 (thickness ≈ 0.05) to prevent cobalt migration at ≥ 500℃, or coated with other ceramic insulating materials; The aforementioned relatively thin thick-film circuit (finished thickness 0.1mm~0.15mm) can be sandwiched between two test pieces 1 with ground surfaces, preventing the ingress of general non-corrosive media. Due to the effective seal between the two test pieces 1, it can also be used in corrosive media conditions. The fabrication method of the thick-film circuit is existing technology and will not be described in detail here; other existing methods can also be used.

[0034] When the circuit layer 2 is a metal-based embedded circuit fabricated on the end face of one of the tested components 1, the fabrication method includes: (1) The part of the test piece 1 that needs to be printed with circuits is processed to form a groove of 0.05mm~0.2mm, leaving space for the circuit to be printed; (2) Sputtering or coating aluminum oxide, zirconium oxide or reinforced aluminum oxide insulating layer on the groove on the end face of the test piece 1 using sputtering process or other methods; (3) Printed resistors made of ruthenium oxide, iridium oxide, etc., and printed conductors and coils made of copper, nickel, titanium, etc., which are then fired and cured when necessary; (4) The circuit is coated again with ceramics such as alumina, zirconium oxide, and toughened alumina to form an outer surface insulating layer; (5) Surface grinding: The circuit part and the end face of the tested part 1 are ground into a plane with a roughness Ra of less than 0.8. When the two metal parts are in contact, the medium and other substances can be prevented from entering.

[0035] The circuit layer 2 is directly processed on the surface of one of the tested components 1. After passing through the protective layer, it can prevent the medium from immersing in, and even if it does immerse, it will not affect the operation of the circuit.

[0036] The circuit layer 2 prepared by these two methods, being ground between the two tested components 1, will not suffer damage along with the circuit's resistance unless the tested component 1 is damaged by cavitation, erosion, or other factors. Otherwise, if the tested component 1 is not damaged by erosion, the circuit will not be damaged either. The circuit layer 2 can withstand high temperatures and even higher thermal shocks for extended periods. Furthermore, by selecting the materials and processes for the substrate, conductors, resistors, and protective layers according to the stability range, the circuit will not break due to thermal expansion and contraction of the tested component 1.

[0037] In this embodiment, considering that the scouring medium is strong cavitation and scouring conditions, the material of the tested component 1 can be metal, preferably an alloy, and more preferably a hard alloy, such as YG8. For environments such as steam, alloys such as 440C can also be used.

[0038] The sensor described in this embodiment can be used for general detection, as well as for digital twins and deep learning. It can be applied to control valves, such as black water angle valves 100, sleeve valves 200, single-seat valves 300, ball valves, and nuclear power valves. It can be applied to the valve core 30, valve seat, and flow channel forming components of control valves, as long as the circuit layer 2 is sandwiched between the two detected components 1 and the connecting surfaces are ground.

[0039] Take its application in valves as an example.

[0040] like Figure 4 As shown, in order to monitor the erosion damage of the sealing surface and profile of the valve core 30 in real time, a sensor is applied to the valve core 30. The valve core 30 includes three segments spliced ​​together. A thick film circuit is sandwiched between any two adjacent segments, or the circuit is directly etched on the splicing surface. The detection part 3 is designed close to the outer circle of each segment of the valve core 30, and the lead-out coil 33 is close to the center so that the detection line can be led out through the hollow valve stem.

[0041] like Figure 5 As shown, in order to monitor the erosion damage of the flow channel forming component of the valve in real time, sensors are used on the flow channel forming component of the valve. Taking the black water angle valve 100 as an example, its flow channel forming component includes an upper sleeve 1001, two middle sleeves 1002, a valve seat body 1003, and a venturi sleeve 1004, which are connected in sequence. Sensors can be installed between the upper sleeve 1001 and the first middle sleeve 1002, between the two middle sleeves 1002, between the second middle sleeve 1002 and the valve seat body 1003, and between the valve seat body 1003 and the venturi sleeve 1004 (these parts have inwardly protruding throttling rings, and erosion generally occurs at the throttling rings, hence the installation of sensors).

[0042] like Figures 7-9 As shown, a sensor is placed on the valve seat to monitor the erosion damage of the valve seat in real time. Figure 7 and Figure 8 Taking the sleeve valve 200 shown as an example, its valve seat includes an upper valve seat 2001 and a lower valve seat 2002 pressed together, and a sensor is disposed between the upper valve seat 2001 and the lower valve seat 2002. Figure 9 The single-seat valve shown has a valve seat comprising a first valve seat 3001 and a second valve seat 3002 pressed together, with a sensor disposed between the first valve seat 3001 and the second valve seat 3002.

[0043] Considering that the sensor's signal contact area also needs to be sealed to the valve, leakage from the valve cannot be caused by the connector. Figure 6 As shown, a connector 20 is mounted on the valve body 10. The connector 20 includes a base 201, an insulator 202, and multiple pins 203; wherein, The base 201 is inserted into the electrical channel 101 of the valve body 10, with one end face abutting against the stepped surface of the electrical channel 101 and the other end face abutting against the electrical end cap 40 that is pressed against it and connected to the valve body 10. The substrate 201 is provided with a through hole 2011, and the insulator 202 is sealed and inserted into the through hole 2011; Multiple pins 203 are spaced apart and embedded within the insulator 202, with their axial direction parallel to the axial direction of the insulator 202. Both ends of the pins extend beyond the insulator 202, and the ends extending inward are electrically connected to a scour damage detection sensor via wires. The number of pins 203 is not less than the number of lead coils 33.

[0044] Sealing rings can be installed between the stepped surfaces of the base 201 and the electrical channel 101, and between the base 201 and the electrical end cap 40, to improve sealing performance. The outer peripheral wall of the insulator 202 and the inner peripheral wall of the base 201 can be configured with a convex-concave fit. This improves both the firmness of the insulator 202 within the perforation 2011 of the base 201 and the sealing performance.

[0045] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A sensor for detecting erosion damage, characterized in that, Includes a circuit layer (2) sandwiched between two tested components (1), the circuit layer (2) having at least one detection section (3); wherein, Each detection unit (3) includes a plurality of resistor components (31) spaced apart from the scouring surface near the test piece (1) to the distance away from the scouring surface, and the plurality of resistor components (31) are connected in parallel.

2. The sensor for detecting erosion damage according to claim 1, characterized in that, Each resistor assembly (31) includes at least two resistors (311) arranged in the profile of a cross section parallel to the circuit layer (2) along the scouring surface. In each detection section (3), the resistors (311) of each resistor assembly (31) are connected in parallel from the closest to the scouring surface to the furthest from the scouring surface.

3. The sensor for detecting erosion damage according to claim 1 or 2, characterized in that, The circuit layer (2) is provided with lead wire trays (33) that correspond one-to-one with the parallel lead wires (32) of the resistor assembly (31) at a position away from the scouring surface. Each parallel lead wire (32) is electrically connected to the corresponding lead wire tray (33).

4. The sensor for detecting erosion damage according to claim 1 or 2, characterized in that, The tested component (1) is provided with a channel (4), and the circuit layer (2) is annular and is sandwiched between the end faces of the two tested components (1) that are perpendicular to the axial direction of the channel (4).

5. The sensor for detecting erosion damage according to claim 4, characterized in that, The detection unit (3) is provided in at least two parts, which are distributed circumferentially along the circuit layer (2).

6. The sensor for detecting erosion damage according to claim 1, characterized in that, The circuit layer (2) is a thick-film circuit; Alternatively, the circuit layer (2) may be a metal-based embedded circuit fabricated on the end face of one of the tested components (1).

7. The sensor for detecting erosion damage according to claim 1, characterized in that, The material of the tested component (1) is metal.

8. A control valve, characterized in that, It includes at least one sensor for detecting scour damage as described in any one of claims 1-7.

9. The control valve according to claim 8, characterized in that, The valve body (10) of the valve is equipped with a connector (20), the connector (20) including a base (201), an insulator (202) and a plurality of pins (203); wherein, The base (201) is inserted into the electrical channel (101) of the valve body (10), with one end face abutting against the stepped surface of the electrical channel (101) and the other end face abutting against the electrical end cap (40) that is pressed against it and connected to the valve body (10); The substrate (201) is provided with a through hole (2011), and the insulator (202) is sealed and inserted into the through hole (2011); Multiple pins (203) are spaced apart and embedded in the insulator (202), with their axial direction parallel to the axial direction of the insulator (202), and both ends of the pins extend beyond the insulator (202). The ends extending inward beyond the insulator (202) are electrically connected to the scour damage detection sensor.

10. The control valve according to claim 8, characterized in that, The control valve is a black water angle valve (100), a sleeve valve (200), a single-seat valve (300), a ball valve, or a nuclear power valve.

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