A circulating water cooling gas cooler leakage monitoring device based on dew point detection

Abstract

A kind of circulating water cold gas cooler leakage monitoring device based on dew point detection, it includes pressure guide line, local instrument box, dew point detector, signal line, main control computer, cooler, local pressure gauge is provided in local instrument box, cooler outlet pipe is installed at the outlet end of cooler, and cooler outlet pipe is connected with one end of pressure guide line.The utility model has the advantages that: the utility model realizes high sensitivity, real-time early warning to the early leakage of circulating water cold gas cooler by directly monitoring the dew point change of cooled gas online;It skillfully utilizes the existing pressure guide line for minimization modification, has the advantages of simple structure, convenient installation, does not affect production;Cooperating with insulation and sealing design ensures the detection reliability, combined with multi-channel switching function and intelligent alarm system, while significantly improving monitoring timeliness and accuracy, effectively reduces comprehensive implementation and operation cost.

Description

Technical Field

[0001] This utility model relates to the field of gas cooler detection technology, specifically to a leak monitoring device for a circulating water-cooled gas cooler based on dew point detection. Background Technology

[0002] In industrial production fields such as chemical, power, and metallurgy, gas coolers using circulating water as a cold source are key heat exchange equipment for ensuring stable process flow and safe equipment operation. Their core function is to effectively cool the gas by exchanging heat between circulating water and high-temperature process gas. However, during long-term operation, factors such as corrosion, fatigue, pressure shock, and material aging of the internal heat exchange tube bundles can easily lead to tube wall damage, resulting in circulating water leakage and contamination of the gas side. If such leaks are not detected and addressed in a timely manner, they will cause a series of serious problems: moisture entering downstream equipment with the process gas can cause equipment corrosion (such as erosion of the copper plating on oxygen compressor impellers), catalyst deactivation, and product contamination; when the leakage increases, it can also cause liquid hammer, directly damaging high-speed rotating equipment (such as compressor impellers), causing increased unit vibration, and even leading to unplanned shutdowns and safety accidents.

[0003] Currently, the conventional methods commonly used in the industry for leak monitoring of circulating water-cooled gas coolers have the following three significant drawbacks: Offline manual detection method: This method relies on operators periodically opening the drain valve at the bottom of the cooler for visual inspection or sampling analysis. This method has a long detection cycle, poor real-time performance, and cannot capture the instantaneous state of a leak; moreover, minute leaks are easily evaporated by high-temperature gases, making accurate manual judgment difficult; in addition, this method is labor-intensive, depends on personnel experience, and carries the risk of missed detections and misjudgments.

[0004] Invasive or complex modification methods: Some online monitoring solutions require the opening of large sampling ports on process pipelines or the installation of complex separation and condensation devices. The modification work is extensive and the installation cost is high. Furthermore, the modification may affect the continuous operation of the production line or even introduce new leaks or failure points.

[0005] Indirect or low-sensitivity monitoring methods: Some methods rely on monitoring changes in cooling water quality (such as conductivity) or using low-precision humidity sensors for indirect detection. The former suffers from severe response lag and is easily affected by factors such as system water replenishment; the latter, due to insufficient sensor accuracy, susceptibility to environmental temperature and pressure, or improper installation location, struggles to accurately and reliably detect early, minute moisture leaks, thus failing to provide effective early warning.

[0006] In summary, existing technologies either cannot achieve real-time online monitoring, are difficult to implement and costly to modify, or lack sufficient detection sensitivity and reliability, making it difficult to meet the urgent needs of modern industrial safety production for early warning and accurate diagnosis. Therefore, there is an urgent need for a leak monitoring device that is easy to modify, can operate online in real time, and has high sensitivity, in order to quickly and accurately identify early leaks in gas coolers and prevent the escalation of the fault. Utility Model Content

[0007] The purpose of this invention is to address the shortcomings and defects of existing technologies by providing a leakage monitoring device for circulating water-cooled gas coolers based on dew point detection. This invention achieves high sensitivity and real-time early warning for early leakage of circulating water-cooled gas coolers by directly monitoring the dew point change of the cooled gas online. It cleverly utilizes existing pressure guiding pipelines with minimal modification, and has the advantages of simple structure, convenient installation, and no impact on production. The insulation and sealing design ensures the reliability of detection. Combined with multi-channel switching function and intelligent alarm system, it significantly improves the timeliness and accuracy of monitoring while effectively reducing the overall implementation and maintenance costs.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: a leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection, comprising a pressure-conducting pipeline, a local instrument box, a dew point detector, a signal line, a main control computer, and a cooler. The local instrument box is equipped with a local pressure gauge. A cooler outlet pipe is installed at the outlet end of the cooler, and the cooler outlet pipe is connected to one end of the pressure-conducting pipeline. The other end of the pressure-conducting pipeline is connected to the first interface of a three-way compression fitting. The pressure-conducting pipeline extends into the local instrument box through the second interface of the three-way compression fitting and is connected to the local pressure gauge. A connecting copper pipe is sealed and connected to the third interface of the three-way compression fitting. The other end of the connecting copper pipe is connected to the dew point detector. The electrical signal of the dew point detector is connected to the main control computer through the signal line.

[0009] Furthermore, each interface of the three-way ferrule connector is provided with a sealing gasket, and the interface size of the three-way ferrule connector matches the diameter of the pressure guiding pipeline and the connecting copper pipe.

[0010] Furthermore, the outer wall of the connecting copper pipe is wrapped with an insulation layer.

[0011] Furthermore, the dew point detector is a high-precision online dew point detector.

[0012] Furthermore, the main control computer has a built-in data processing module and an alarm module. The data processing module is used to display and store gas dew point data in real time, and the alarm module is used to trigger an audible and visual alarm and push information when the gas dew point value exceeds a preset threshold.

[0013] Furthermore, it also includes a multi-channel switching valve, which is disposed between the connecting copper pipe and the dew point detector. The multi-channel switching valve includes a common output terminal and at least two selection input terminals. The common output terminal is connected to the detection inlet of the dew point detector, and the selection input terminals are respectively connected to the pressure guiding pipelines of different gas cooler systems through corresponding connecting copper pipes and tee fittings.

[0014] Furthermore, it also includes an analysis chamber, in which the dew point detector is installed.

[0015] After adopting the above technical solution, the beneficial effects of this utility model are as follows: This utility model has at least the following advantages: 1. Achieved high sensitivity and high reliability in real-time online monitoring: This device can detect changes in trace moisture content in the gas with extreme sensitivity by directly and continuously monitoring the dew point temperature of the cooled gas. The dew point detection technology itself is extremely sensitive to moisture. Combined with a high-precision online dew point meter, it can identify water content fluctuations caused by very early and minute leaks, achieving true early warning. The monitoring signal is transmitted to the main control computer in real time through the signal line, completely changing the lagging mode of traditional manual periodic inspection.

[0016] 2. Simple modification, low implementation cost, and no impact on the main process: This unit utilizes the existing pressure-conducting pipeline for the gas cooler outlet pressure detection. Only a three-way compression fitting needs to be installed on the pressure-conducting pipeline near the local pressure gauge, and a connecting copper pipe needs to be laid to the dew point meter. No cutting or welding of the main process pipeline is required, the modification work is minimal, installation is quick, and it has almost no impact on the normal operation of the production line, significantly reducing the initial investment and implementation risk of equipment modification.

[0017] 3. Simple and stable structure, convenient maintenance: The entire monitoring device consists of mature pipe joints, standard instruments, and universal signal transmission equipment, with no complex mechanical or moving parts, resulting in high structural reliability. Routine maintenance mainly focuses on the periodic calibration of the dew point detector and routine checks on the pipe sealing, requiring minimal maintenance and inexpensive costs.

[0018] 4. Strong anti-interference capability and accurate and reliable data: By using sealing gaskets to ensure the airtightness of each interface and setting an insulation layer outside the connecting copper pipe, the influence of ambient temperature fluctuations on the state of the sampled gas is effectively blocked. These measures minimize external interference, ensure the representativeness of the sampled gas, and enable the data measured by the dew point detector to truly and accurately reflect the leakage status inside the cooler.

[0019] 5. Excellent scalability and cost-effectiveness: By adding a multi-channel switching valve, the detection inlet of a high-precision dew point meter can be switched alternately to the monitoring loops of multiple gas coolers. This design allows one core detection device to serve multiple coolers, meeting multi-point monitoring needs while significantly reducing the equipment investment cost per monitoring point, making it particularly suitable for plants with multiple similar devices.

[0020] 6. Intelligent alarm and data management: The main control computer integrates a data processing and alarm module, which can not only display and record historical dew point trends in real time to provide data support for fault diagnosis, but also automatically trigger audible and visual alarms and remote information push (such as SMS) when the dew point value exceeds the preset safety threshold, ensuring that managers can be notified of the alarm and take measures as soon as possible, thus improving the intelligence and initiative of operation and maintenance management. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of this utility model.

[0023] Figure 2 This is a schematic diagram of the structure of the multi-channel switching valve installed in this utility model.

[0024] Explanation of reference numerals in the attached diagram: 1. Cooler outlet pipe; 2. Pressure guide pipe; 3. Local instrument box; 4. Local pressure gauge; 5. Three-way compression fitting; 6. Connecting copper pipe; 7. Analysis chamber; 8. Dew point detector; 9. Signal line; 10. Main control computer; 11. Multi-channel switching valve; 12. Cooler. Detailed Implementation

[0025] See Figure 1As shown, the technical solution adopted in this specific embodiment is as follows: It includes a pressure guiding pipeline 2, a local instrument box 3, a dew point detector 8, a signal line 9, a main control computer 10, and a cooler 12. The local instrument box 3 is equipped with a local pressure gauge 4. A cooler outlet pipe 1 is installed at the outlet end of the cooler 12, and the cooler outlet pipe 1 is connected to one end of the pressure guiding pipeline 2. The other end of the pressure guiding pipeline 2 is connected to the first interface of a three-way compression fitting 5. The pressure guiding pipeline 2 extends into the local instrument box 3 through the second interface of the three-way compression fitting 5 and is connected to the local pressure gauge 4. A connecting copper pipe 6 is sealed and connected to the third interface of the three-way compression fitting 5. The other end of the connecting copper pipe 6 is connected to the dew point detector 8. The electrical signal of the dew point detector 8 is connected to the main control computer 10 through the signal line 9.

[0026] More specifically, each interface of the three-way ferrule connector 5 is equipped with a sealing gasket, and the interface size of the three-way ferrule connector 5 matches the diameter of the pressure-conducting pipeline 2 and the connecting copper pipe 6. The sealing gaskets ensure the sealing effect of the three-way ferrule connector 5 during connection, preventing gas leakage from affecting the detection accuracy.

[0027] More specifically, the outer wall of the connecting copper pipe 6 is wrapped with an insulation layer. The insulation layer can prevent changes in the external ambient temperature from affecting the temperature of the gas inside the pipe, thereby ensuring the detection accuracy of the dew point detector.

[0028] More specifically, the dew point detector 8 is a high-precision online dew point meter. The dew point detector 8 has a detection range of -80℃ to 20℃ dew point temperature, and a detection accuracy of no less than ±0.5℃, enabling it to capture changes in gas moisture content caused by minute leaks.

[0029] More specifically, the main control computer 10 has a built-in data processing module and an alarm module. The data processing module is used to display and store gas dew point data in real time, and the alarm module is used to trigger an audible and visual alarm and push information when the gas dew point value exceeds a preset threshold.

[0030] More specifically, it also includes an analysis chamber 7, within which a dew point meter 8 is installed. The analysis chamber 7 provides better protection for the dew point meter 8 and ensures its accuracy.

[0031] See Figure 2As shown, a leak monitoring device for a circulating water-cooled gas cooler based on dew point detection also includes a multi-channel switching valve 11. The multi-channel switching valve 11 is positioned between the connecting copper pipe 6 and the dew point detector 8. The multi-channel switching valve 11 includes a common output terminal and at least two selection input terminals. The common output terminal is connected to the detection inlet of the dew point detector 8, and the selection input terminals are respectively connected to the pressure-conducting pipelines 2 of different gas cooler systems via corresponding connecting copper pipes 6 and tee fittings 5. By setting up the multi-channel switching valve 11, multiple coolers can be quickly detected, thereby enabling one dew point detector 8 to monitor multiple coolers 12 in turn, thus reducing equipment investment costs.

[0032] The working principle of this invention is as follows: When the cooler 12 is running, the gas flowing out of its outlet enters the pressure-conducting pipeline 2 through the cooler outlet pipe 1. Most of the gas flows along the pressure-conducting pipeline to the local pressure gauge 4 for routine pressure monitoring; simultaneously, a portion of the gas is diverted through the three-way compression fitting 5 installed on the pressure-conducting pipeline 2 and enters the connecting copper pipe 6. This diverted gas serves as a test sample and is transported to the dew point detector 8. The dew point detector directly and accurately reflects the moisture content and humidity of the gas by measuring its dew point temperature. If the gas cooler leaks, circulating water seeps into the gas side, causing an increase in gas humidity and dew point temperature. The dew point detector 8 transmits the detected analog or digital signal to the main control computer 10 in real time via signal line 9. The main control computer 10 processes, displays, and records the data and compares it with a preset safety threshold. Once the detected dew point value continuously or momentarily exceeds the threshold, the system determines that a leak has occurred and triggers the alarm module, realizing audible and visual warnings and remote information push. The multi-channel switching valve 11 can detect gas samples from different coolers in turn, realizing integrated monitoring with multiple functions.

[0033] The above is only used to illustrate the technical solution of this utility model and not to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model, as long as they do not depart from the spirit and scope of the technical solution of this utility model, should be covered within the scope of the claims of this utility model.

Claims

1. A leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection, characterized in that: It includes a pressure-conducting pipeline (2), a local instrument box (3), a dew point detector (8), a signal line (9), a main control computer (10), and a cooler (12). The local instrument box (3) is equipped with a local pressure gauge (4). A cooler outlet pipe (1) is installed at the outlet end of the cooler (12), and the cooler outlet pipe (1) is connected to one end of the pressure-conducting pipeline (2). The other end of the pressure-conducting pipeline (2) is connected to the first interface of a three-way compression fitting (5). The pressure-conducting pipeline (2) extends into the local instrument box (3) through the second interface of the three-way compression fitting (5) and is connected to the local pressure gauge (4). A connecting copper pipe (6) is sealed and connected to the third interface of the three-way compression fitting (5). The other end of the connecting copper pipe (6) is connected to the dew point detector (8). The electrical signal of the dew point detector (8) is connected to the main control computer (10) through the signal line (9).

2. The leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection according to claim 1, characterized in that: Each interface of the three-way compression fitting (5) is provided with a sealing gasket, and the interface size of the three-way compression fitting (5) matches the diameter of the pressure guiding pipeline (2) and the connecting copper pipe (6).

3. The leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection according to claim 1, characterized in that: The outer wall of the connecting copper pipe (6) is wrapped with a heat insulation layer.

4. A leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection according to claim 1, characterized in that: The dew point detector (8) is a high-precision online dew point detector.

5. A leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection according to claim 1, characterized in that: The main control computer (10) has a built-in data processing module and an alarm module. The data processing module is used to display and store gas dew point data in real time, and the alarm module is used to trigger an audible and visual alarm and push information when the gas dew point value exceeds a preset threshold.

6. A leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection according to claim 1, characterized in that: It also includes a multi-channel switching valve (11), which is set between the connecting copper pipe (6) and the dew point detector (8). The multi-channel switching valve (11) includes a common output terminal and at least two selection input terminals. The common output terminal is connected to the detection inlet of the dew point detector (8), and the selection input terminals are respectively connected to the pressure guiding pipelines (2) of different gas cooler systems through the corresponding connecting copper pipe (6) and the three-way compression fitting (5).

7. A leakage monitoring device for a circulating water-cooled gas cooler based on dew point detection according to claim 1, characterized in that: It also includes an analysis chamber (7), in which the dew point detector (8) is installed.

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