Large-diameter ball valve complex diagnostic system and diagnostic method using the same

Abstract

A large-diameter ball valve combined diagnostic system and a diagnostic method using the same are disclosed. A large-diameter ball valve combined diagnostic system according to an embodiment of the present invention comprises: a diagnostic gas injection unit connected to a pipe in which a large-diameter ball valve to be diagnosed is installed, for introducing gas into the interior of the large-diameter ball valve to be diagnosed; a diagnostic gas discharge unit having a structure communicating with the diagnostic gas injection unit and exhausting the gas introduced into the interior of the large-diameter ball valve to the outside under the control of an operator; a differential pressure diagnostic unit mounted in a structure communicating with the pipe in which the large-diameter ball valve to be diagnosed is installed, and equipped with a differential pressure gauge inlet valve and a differential pressure gauge drain valve; a bubble diagnostic unit having a valve structure utilized in a bubble diagnostic method, mounted in a structure communicating between the diagnostic gas injection unit and the diagnostic gas discharge unit; and a balloon diameter diagnostic unit having a valve structure utilized in a balloon diameter diagnostic method, mounted in a structure communicating between the diagnostic gas injection unit and the diagnostic gas discharge unit. The gist of the configuration is to include a flow-type diagnostic unit that is mounted in a structure communicating with the piping on which the large-diameter ball valve to be diagnosed is installed, and is equipped with an inspection outlet, an electronic flow meter, and an outlet valve.

Description

Technology Field

[0001] The present invention relates to a complex diagnostic system for large-diameter ball valves and a diagnostic method using the same. More specifically, it relates to a complex diagnostic system capable of integrating four diagnostic methods into a single device to diagnose abnormalities in large-diameter ball valves having an inner diameter of 6 inches or more, and a diagnostic method using the same. Background Technology

[0002] Large-diameter ball valves are used as major fluid control devices in industrial settings, and in particular, large-diameter ball valves with an inner diameter of 6 inches or more are essential components of large-scale piping systems. Due to the size and structural characteristics of these large-diameter ball valves, it is very important to accurately diagnose whether there is internal leakage. However, there are several problems with conventional technology that prevent this from being effectively performed.

[0003] First, conventional diagnostic methods for large-diameter ball valves are designed to perform various diagnostic methods—such as differential pressure, bubble, balloon diameter, and flow rate methods—through separate, independent equipment. Since the operation of each piece of equipment is distinct and complex, this requires operators to possess a high level of proficiency during the diagnostic process. This structural complexity reduces operational efficiency and unnecessarily prolongs diagnostic time.

[0004] Furthermore, since each diagnostic device operates independently, operators require excessive time and effort in the process of collecting and comprehensively analyzing diagnostic data. In particular, when inconsistencies arise between data acquired from different devices, the reliability of the diagnostic results decreases, frequently necessitating additional verification processes.

[0005] In conventional technology, greenhouse gases are frequently used as a medium in differential pressure diagnostic methods. The greenhouse gases emitted during this diagnostic process have a serious impact on the environment and are identified as one of the major causes of air pollution. Despite the need for alternative technologies that do not use greenhouse gases, sufficient efforts have not been made in conventional technology to address these environmental issues.

[0006] The work preparation process is also a prime example of the inefficiency of conventional technology. Due to the independent nature of the diagnostic equipment, the process of installing each device on-site and connecting it to the piping is complex. This results in excessive preparation time and imposes an additional burden on the operator, requiring them to repeatedly check the connection status between the equipment during the work process.

[0007] Furthermore, conventional diagnostic methods are limited to specific techniques, making it difficult to comprehensively analyze abnormalities in large-diameter ball valves by combining various methods. This fragmented diagnostic approach poses a significant obstacle to obtaining comprehensive and reliable diagnostic results regarding internal leakage in ball valves.

[0008] Due to their size and complexity, large-diameter ball valves often make it difficult to move and install diagnostic equipment. In particular, if the location where the ball valve to be diagnosed is installed is cramped or has poor accessibility, physical constraints arise during the process of moving each piece of equipment, which hinders the smooth progress of the work.

[0009] The lack of compatibility between diagnostic equipment is also one of the major problems with conventional technology. Independently developed diagnostic devices are optimized for specific manufacturers or models, resulting in poor interoperability even when diagnosing the same ball valve. This requires additional cost and time when replacing or upgrading diagnostic equipment.

[0010] The difficulties in managing data during the diagnostic process are also cited as a limitation of conventional technology. Manual data recording and analysis increase the likelihood of human error and make systematic data management difficult. This issue also negatively impacts the accuracy and reliability of diagnostic result reports.

[0011] Consequently, conventional technology causes temporal, economic, and environmental inefficiencies in the diagnosis of large-diameter ball valves, posing a significant limitation in failing to meet the demands of industrial sites that require the rapid and accurate determination of valve abnormalities. These issues not only lead to a decline in industrial productivity but also, in the long term, contribute to the exacerbation of social problems such as environmental pollution.

[0012] The present invention aims to solve the problems of the prior art. By providing a complex and integrated diagnostic system for large-diameter ball valves, the present invention focuses on improving operational efficiency, minimizing environmental impact, and ensuring the reliability of diagnostic results. Prior art literature

[0013] Korean Patent Publication No. 10-1944464 (Registration Date: January 25, 2019) The problem to be solved

[0014] The objective of the present invention is to provide a large-diameter ball valve composite diagnostic system and a diagnostic method using the same, which can solve the problems associated with the inefficient conventional technology of having to perform four diagnostic methods using different equipment to diagnose abnormalities in large-diameter ball valves having an inner diameter of 6 inches or more; can perform differential pressure diagnostic methods, bubble diagnostic methods, balloon diameter diagnostic methods, and flow rate diagnostic methods through a single system, thereby standardizing and systematizing the internal leakage inspection method for ball valves; can solve the problem of atmospheric environmental pollution caused by greenhouse gases used in the differential pressure diagnostic method according to the conventional technology; can simplify the work preparation process required for the abnormality diagnosis process of large-diameter ball valves and reduce the time required for work; and can secure high reliability of the abnormality diagnosis results for large-diameter ball valves. means of solving the problem

[0015] A large-diameter ball valve composite diagnostic system and a diagnostic method using the same according to one aspect of the present invention for achieving such an objective comprises: a diagnostic gas injection unit connected to a pipe in which a large-diameter ball valve to be diagnosed is installed, for introducing gas into the interior of the large-diameter ball valve to be diagnosed; a diagnostic gas discharge unit having a structure communicating with the diagnostic gas injection unit and exhausting the gas introduced into the interior of the large-diameter ball valve to the outside under the control of an operator; a differential pressure diagnostic unit mounted in a structure communicating with the pipe in which the large-diameter ball valve to be diagnosed is installed, and equipped with a differential pressure gauge inlet valve and a differential pressure gauge drain valve; a bubble diagnostic unit having a valve structure utilized in a bubble diagnostic method, mounted in a structure communicating between the diagnostic gas injection unit and the diagnostic gas discharge unit; and a balloon diameter diagnostic unit having a valve structure utilized in a balloon diameter diagnostic method, mounted in a structure communicating between the diagnostic gas injection unit and the diagnostic gas discharge unit. The configuration may include a flow-type diagnostic unit that is mounted in a structure communicating with the piping in which the large-diameter ball valve to be diagnosed is installed, and is equipped with an inspection outlet, an electronic flow meter, and an outlet valve.

[0016] In one embodiment of the present invention, the diagnostic gas injection unit may comprise: a strainer having a structure that removes foreign substances entering the pipe during the process of injecting natural gas, not greenhouse gas, into the pipe where the large-diameter ball valve to be diagnosed is installed for diagnosis, injecting only 10% of the volume compared to the injection amount according to the prior art; a digital pressure gauge having a structure that detects gas pressure in the pipe system in real time and is mounted in a structure that communicates with the pipe where the large-diameter ball valve to be diagnosed is installed; a leak indicator having a structure that detects gas leakage in the pipe system in real time and is mounted in a structure that communicates with the pipe where the large-diameter ball valve to be diagnosed is installed; and a leak judgment output unit having a structure that lights lamps of different colors according to the amount of gas leakage based on data obtained from the leak indicator and simultaneously outputs different warning sounds.

[0017] In one embodiment of the present invention, the diagnostic gas discharge unit may be configured to include a silencer having a structure that absorbs noise generated during the exhaust process, which is mounted on one end of a pipe that exhausts gas introduced into the interior of a large-diameter ball valve to the outside.

[0018] In one embodiment of the present invention, the large-diameter ball valve composite diagnostic system may comprise: an output printer having a structure that collects diagnostic result data obtained through the differential pressure diagnostic unit, bubble diagnostic unit, balloon diameter diagnostic unit, and flow rate diagnostic unit, and then outputs a result report in a preset format; and a movable trolley having a structure that is movable, with the diagnostic gas injection unit, diagnostic gas discharge unit, differential pressure diagnostic unit, bubble diagnostic unit, balloon diameter diagnostic unit, and flow rate diagnostic unit mounted on the upper part and wheels mounted on the lower part.

[0019] The present invention may also provide a diagnostic method using a large-diameter ball valve complex diagnostic system. A diagnostic method using a large-diameter ball valve complex diagnostic system according to one aspect of the present invention comprises: a field movement step of moving to a location where a large-diameter ball valve to be diagnosed is located using a mobile trolley of the large-diameter ball valve complex diagnostic system; a high-pressure hose connection step of installing a pipe in a structure communicating with the large-diameter ball valve to be diagnosed and installing a high-pressure hose for injecting gas into the ball valve; a connection leak inspection step of confirming a stable connection state between the pipe and the high-pressure hose connected in the high-pressure hose connection step; and a small-volume discharge step of injecting gas into the large-diameter ball valve to be diagnosed through the high-pressure hose, wherein natural gas, not greenhouse gas, is injected into the pipe where the large-diameter ball valve to be diagnosed is installed for diagnosis, and only 10% of the volume compared to the injection amount according to the prior art is injected. The method may comprise: a differential pressure measurement step for performing a differential pressure diagnostic method using a differential pressure gauge inlet valve and a differential pressure gauge drain valve installed in a structure communicating with the piping on which the large-diameter ball valve on which the diagnostic target is installed; a bubble measurement step for performing a bubble diagnostic method using a valve utilized in a bubble diagnostic method installed in a structure communicating between the diagnostic gas injection part and the diagnostic gas discharge part; a flow measurement step for performing a flow diagnostic method using an inspection outlet, an electronic flow meter, and an outlet valve installed in a structure communicating with the piping on which the large-diameter ball valve on which the diagnostic target is installed; and a residual gas discharge step for exhausting gas remaining inside the piping communicating with the large-diameter ball valve on which the diagnostic target is installed to the outside through the diagnostic gas discharge part. Effects of the invention

[0020] As explained above, according to the large-diameter ball valve composite diagnostic system of the present invention, by providing a diagnostic gas injection unit, a diagnostic gas discharge unit, a differential pressure diagnostic unit, a bubble diagnostic unit, a balloon diameter diagnostic unit, and a flow rate diagnostic unit of a specific structure, the differential pressure diagnostic method, the bubble diagnostic method, the balloon diameter diagnostic method, and the flow rate diagnostic method can be performed through a single system, thereby standardizing and configuring the internal leakage inspection method for ball valves, simplifying the work preparation process required for the diagnosis of abnormalities in large-diameter ball valves, and shortening the work time, it is possible to solve the problems associated with the inefficient conventional technology that required performing four diagnostic methods using different equipment to diagnose abnormalities in large-diameter ball valves having an inner diameter of 6 inches or more.

[0021] In addition, according to the diagnostic method using the large-diameter ball valve composite diagnostic system of the present invention, by providing a field movement step for performing specific processes, a high-pressure hose connection step, a connection leak inspection step, a small amount discharge step, a differential pressure measurement step, a bubble measurement step, a flow rate measurement step, and a residual gas discharge step, differential pressure diagnostic methods, bubble diagnostic methods, balloon diameter diagnostic methods, and flow rate diagnostic methods can be performed through a single system, thereby standardizing and systematizing the internal leak inspection method for ball valves, resolving the problem of atmospheric environmental pollution caused by greenhouse gases used in the differential pressure diagnostic method according to the prior art, simplifying the work preparation process required for the diagnosis of abnormalities in large-diameter ball valves and shortening the work time, and ensuring high reliability of the diagnosis results for abnormalities in large-diameter ball valves. Brief explanation of the drawing

[0022] FIG. 1 is a plan view and a front view showing a large-diameter ball valve composite diagnostic system according to one embodiment of the present invention. FIG. 2 is a block diagram showing a test controller of a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention. FIG. 3 is a block diagram showing the piping line of a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention. FIG. 4 is a block diagram showing the control lines of the leak indicator and leak judgment output unit of a large-diameter ball valve composite diagnostic system according to one embodiment of the present invention. FIG. 5 is a photograph showing a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention. FIG. 6 is a block flowchart illustrating a diagnostic method using a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention. FIG. 7 is a table showing specific measurement methods and diagnostic criteria for a diagnostic method using a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention. Specific details for implementing the invention

[0023] Preferred embodiments of the present invention will be described in detail below with reference to the drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, but should be interpreted in a meaning and concept consistent with the technical spirit of the present invention.

[0024] Throughout this specification, when it is stated that one component is located "on" another component, this includes not only cases where one component is in contact with another component, but also cases where another component exists between the two components. Throughout this specification, when it is stated that a part "includes" a component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0025] FIG. 1 shows a plan view and a front view of a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention, FIG. 2 shows a block diagram showing a test controller of a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention, and FIG. 3 shows a block diagram showing a piping line of a large-diameter ball valve combined diagnostic system according to one embodiment of the present invention.

[0026] Referring to these drawings, the large-diameter ball valve composite diagnostic system (100) according to the present embodiment is equipped with a diagnostic gas injection unit (110), a diagnostic gas discharge unit (120), a differential pressure diagnostic unit (130), a bubble diagnostic unit (140), a balloon diameter diagnostic unit (150), and a flow rate diagnostic unit (160) of a specific structure, thereby enabling the differential pressure diagnostic method, the bubble diagnostic method, the balloon diameter diagnostic method, and the flow rate diagnostic method to be performed through a single system, thus standardizing and configuring the internal leakage inspection method for the ball valve, simplifying the work preparation process required for the diagnosis of abnormalities in the large-diameter ball valve, and shortening the work time, thereby solving the problems associated with the inefficient conventional technology that required performing four diagnostic methods using different equipment to diagnose abnormalities in a large-diameter ball valve having an inner diameter of 6 inches or more.

[0027] Hereinafter, with reference to FIGS. 1 to 7, each component constituting the large-diameter ball valve composite diagnostic system (100) according to the present embodiment will be described in detail. In addition, a diagnostic method using the large-diameter ball valve composite diagnostic system will also be described in detail.

[0028] Specific configuration and role of the diagnostic gas injection unit (110)

[0029] The diagnostic gas injection unit (110) is a device that injects diagnostic gas into the interior of a large-diameter ball valve and is one of the core components of the invention. This injection unit is designed with a structure that efficiently delivers gas into the pipe while simultaneously preventing the entry of foreign substances from the external environment. The injection unit includes a strainer, which serves to remove foreign substances before the gas enters the pipe. This minimizes contamination problems that may occur inside the pipe and ensures accurate diagnostic results.

[0030] The diagnostic gas injection unit (110) uses natural gas as a diagnostic medium, replacing the greenhouse gas used in conventional technology. This enables a stable gas supply required during the diagnostic process while drastically reducing environmental pollution issues. In particular, it is designed to inject only about 10% of the gas used in conventional technology, providing an economic advantage of reducing gas consumption while maximizing efficiency. Additionally, a digital pressure gauge is installed to detect the gas pressure inside the pipe in real time during the injection process, allowing the operator to continuously monitor the gas pressure and take immediate action if necessary.

[0031] The diagnostic gas injection unit (110) includes a leak indicator for detecting gas leakage in real time and a leak judgment output unit for visually indicating the leakage status. The leak judgment output unit lights up lamps of different colors according to the amount of gas leakage and simultaneously outputs a warning sound to help the operator immediately recognize the problem. This design enhances the safety of the diagnostic operation and enables a rapid response in the event of a problem. In addition, all components of the gas injection unit are simple and intuitive to operate, allowing the operator to use them efficiently without any separate complex procedures.

[0032] Specific Structure and Role of the Strainer

[0033] The strainer is a key component of the diagnostic gas injection unit and serves to remove foreign substances before the diagnostic gas enters the piping. By filtering out contaminants that may accumulate inside the piping in advance, it plays a crucial role in increasing diagnostic accuracy and preventing damage to the device. The use of the strainer ensures that the piping system remains more stable and enables precise diagnostic operations.

[0034] The strainer consists of a mesh-type filter and is designed to efficiently block fine particles without obstructing the flow of gas during the diagnostic process. The filter is made of a durable material and can operate stably even in high-pressure and high-temperature environments. In this invention, such a strainer is integrated inside the diagnostic gas injection unit to save installation space and simplify the system.

[0035] The removal of foreign matter through a strainer prevents blockages that may occur during the diagnostic process, thereby maintaining the stability of gas flow. It serves as an essential element, particularly in large-scale piping systems such as large-diameter ball valves, and contributes to extending the lifespan of the device. The operating principle of the strainer utilizes a physical blocking method, which has the advantage of being easy to maintain.

[0036] Regular maintenance of the strainer is essential for maintaining system stability. Foreign matter accumulated in the strainer must be removed at regular intervals, and to this end, the filter is designed with a detachable structure. Operators can easily detach, clean, or replace the strainer, thereby increasing the efficiency of maintenance work.

[0037] Strainers provide high efficiency in removing foreign substances, but using an excessively fine filter can cause resistance to gas flow. In this invention, this problem is solved by optimizing the filter size and material, and the performance of removing foreign substances is maximized without obstructing gas flow.

[0038] Specific structure and role of digital pressure gauges

[0039] Digital pressure gauges are devices that measure and display the pressure of gases inside pipelines in real time, and are essential for ensuring the accuracy and stability of diagnostic operations. They enable operators to continuously monitor the pressure status of the pipelines and take immediate action as necessary. In particular, they enhance system safety by preventing excessive pressure in advance, especially under high-pressure conditions.

[0040] Digital pressure gauges feature high-precision sensors that detect minute pressure changes and provide information to the operator via a digital display. These displays are designed with an intuitive interface to allow operators to easily view data. Some models include warning notifications that output visual or auditory signals when pressure exceeds set limits.

[0041] In addition to providing data in real time, digital pressure gauges support recording and analysis functions. This allows the results of diagnostic operations to be generated into reports or utilized as a database for future diagnoses. Through the digital output function, data can be transmitted to external devices, enabling monitoring and control of the entire system.

[0042] The main advantages of a pressure gauge are high precision and stability. This invention is designed to provide accurate data even in high-temperature and high-pressure environments by using a pressure gauge with enhanced durability. This enables operators to perform more reliable diagnoses and effectively control potential risks that may occur during diagnosis.

[0043] While digital pressure gauges provide precise data, there is a risk that the sensor may be damaged in high-pressure environments. To address this issue, the present invention applies a design that enhances the durability of the pressure gauge sensor and protects it from external shocks or environmental factors. This extends the overall reliability and lifespan of the diagnostic system.

[0044] Specific Structure and Role of the Leakage Indicator

[0045] A leak indicator is a device that detects gas leaks within pipes in real time, playing a crucial role in enhancing the safety and efficiency of diagnostic operations. This device determines the presence of a leak by measuring the gas concentration inside the pipes, enabling the identification of unexpected problems in advance during the diagnostic process.

[0046] The leak indicator accurately measures changes in gas concentration using a high-sensitivity sensor, and this data is displayed on a screen for the operator to check in real time. In this invention, a sensor designed for natural gas is used to minimize malfunctions caused by the type of gas. This enables more accurate leak detection.

[0047] The operating principle of the leak indicator is to output a warning signal when the gas concentration exceeds a set threshold. This signal is provided in either a visual or electrical form, allowing the operator to immediately recognize the problem. In particular, it is designed to detect even minute leaks that may occur in large systems, such as large-diameter ball valves.

[0048] The leak indicator operates continuously, allowing operators to check the system status without additional configuration. This contributes to improved diagnostic convenience and reduces unnecessary steps. Additionally, the warning signal is automatically activated when a leak exceeding a certain level is detected, shortening the operator's response time.

[0049] In this invention, the sensitivity of the leak indicator has been improved to enable accurate detection of even minute leaks. To overcome the limitations of leak detection in existing technologies, a high-sensitivity sensor was applied, and a structural design was introduced to minimize the influence of the external environment. Through this, the leak indicator contributes to increasing the reliability of diagnosis.

[0050] Specific structure and role of the leakage detection output unit

[0051] The leak detection output unit is a device that provides the operator with visual and auditory signals regarding the leak status based on data detected by the leak indicator. This allows the operator to intuitively verify the presence of a leak without having to interpret complex data. This intuitiveness contributes to rapid problem solving at the work site.

[0052] The leak detection output unit indicates the leak status through multi-color LED lamps and warning sounds. When the gas leak is small, a green lamp lights up; as the leak increases, it changes to yellow and then red, while simultaneously adjusting the volume and frequency of the warning sound. This allows the operator to immediately assess the severity of the leak.

[0053] The leak detection output unit features enhanced data processing capabilities to rapidly analyze data input from the leak indicator. The results of this analysis are immediately transmitted to the operator and can provide additional information regarding the location or amount of the leak. This offers more detailed information than the existing simple warning method.

[0054] In the present invention, the leakage detection output unit is designed so as not to be affected by the external environment. Visual and auditory signals are clearly transmitted even in noisy or brightly lit environments at the work site, and the frequency and volume of the warning sound are adjusted to a level that does not impede the operator's work efficiency.

[0055] The leakage detection output unit is designed to enhance signal intuitiveness while providing detailed information. This enables operators to go beyond simply checking warning signals to analyze the cause of the problem and take prompt follow-up actions. In this invention, these elements have been optimized to maximize practicality in the field.

[0056] Specific composition and role of the diagnostic gas radiation unit (120)

[0057] The diagnostic gas discharge unit (120) is a device that discharges gas injected into the large-diameter ball valve being diagnosed to the outside, and is an essential component of the diagnostic process. This discharge unit is designed to quickly and safely remove residual gas inside the piping at the end of the diagnostic operation. This prevents excessive accumulation of gas and increases operational safety.

[0058] The diagnostic gas discharge unit includes a silencer to minimize noise that may occur during the discharge process. The silencer controls the flow of high-pressure gas discharged through the piping to suppress noise generation, thereby maintaining the comfort of the working environment. In this invention, the durability of the silencer is enhanced, and it is optimized to operate stably across various pressure ranges.

[0059] The diagnostic gas discharge unit is designed with a high-efficiency discharge structure to ensure smooth gas release. Installed at one end of the piping, the discharge unit minimizes gas flow resistance during discharge, enabling rapid release. During this process, it stably maintains pressure changes within the piping, preventing the risk of additional gas leakage.

[0060] The diagnostic gas discharge unit also plays an important role in terms of environmental protection. In this invention, natural gas is used instead of greenhouse gases to minimize environmental pollution generated during the emission process. Furthermore, it is designed to emit only the minimum necessary amount of gas by including a valve that controls the gas emission volume. This prevents resource waste and enhances economic efficiency.

[0061] The diagnostic gas discharge unit is designed with ease of use in mind. It provides an intuitive interface that allows the operator to control the discharge process with simple operations, and each component of the discharge unit is designed for easy maintenance. The discharge unit of the present invention provides a device that simultaneously satisfies safety and environmental suitability while maximizing operational efficiency.

[0062] Specific structure and role of the silencer

[0063] The silencer is a key component of the diagnostic gas discharge unit (120) and plays a role in effectively suppressing the noise of gas discharge generated during the diagnostic process. In large-diameter ball valve diagnostic work, high noise can be generated when high-pressure gas is discharged through the piping, which can have a negative effect on the hearing health of workers and reduce the comfort of the working environment. The silencer is designed to solve these problems and reduces the discharge noise to an acceptable level, thereby creating a safe and efficient working environment.

[0064] A silencer is designed with a structure that disperses gas flow and controls pressure. Generally, it includes porous materials or internal baffles to reduce the velocity and disperse energy as the gas passes through the silencer. In this invention, materials such as special alloys or stainless steel capable of withstanding high temperatures and pressures are used to enhance the durability of the silencer. This structure provides stable performance even during long-term use and enables reliable operation in various industrial environments.

[0065] The silencer is designed with ease of maintenance in mind. It is manufactured with a detachable structure to remove gas residue or foreign substances that may accumulate inside, allowing for optimal performance to be maintained through regular inspection and cleaning. Furthermore, the simple installation and replacement of the silencer enhance work efficiency. In this invention, the design of the silencer is optimized to effectively reduce gas emission noise while maximizing emission efficiency and durability.

[0066] Specific configuration and role of the differential pressure diagnostic unit (130)

[0067] The differential pressure diagnostic unit (130) is a device that determines whether there is a leak by measuring the pressure difference based on the gas flow inside the large-diameter ball valve. This diagnostic unit includes a differential pressure gauge inlet valve and a differential pressure gauge drain valve, and detects whether there is a leak by comparing the gas pressure at a specific point in the piping. Through this, the sealing performance of the large-diameter ball valve can be precisely evaluated.

[0068] The differential pressure diagnostic unit is centered around a high-precision differential pressure gauge that detects pressure differences occurring as gas passes through a large-diameter ball valve. The differential pressure gauge measures pressure changes between two measurement points in real time and converts them into data. This data enables operators to analyze the gas flow status and potential leaks within the piping.

[0069] This device is useful for detecting not only gas leaks but also internal valve damage or abnormal pressure changes. In particular, for equipment with complex internal structures and large dimensions, such as large-diameter ball valves, pressure-change-based diagnosis is effective for identifying leak locations. The differential pressure diagnostic unit provides this information, enabling efficient planning of maintenance and repairs.

[0070] The differential pressure diagnostic unit is designed with ease of operation in mind. It can be easily connected to the piping under diagnosis via the differential pressure gauge inlet and drain valves, allowing the operator to control gas flow or regulate the pressure inside the piping. Additionally, data is provided digitally, enabling the operator to check analysis results in real time and utilize them for generating diagnostic reports.

[0071] In this invention, a high-quality differential pressure gauge is used to maximize the accuracy and durability of the differential pressure diagnostic unit, and the entire device is manufactured from a corrosion-resistant material. This enables stable operation in various industrial environments and provides an efficient diagnostic solution capable of reliably evaluating abnormalities in large-diameter ball valves.

[0072] Specific configuration and role of the bubble-type diagnostic unit (140)

[0073] The bubble-type diagnostic unit (140) is a device used to check for leaks inside a large-diameter ball valve and detects leaks through the process of generating bubbles of gas within the piping. This device determines the leak condition by observing whether bubbles are generated at the point where the gas flow should be blocked. The diagnostic method using bubbles is simple and intuitive, so it is widely used in industrial settings.

[0074] The bubble-type diagnostic unit is mounted between the diagnostic gas injection unit and the discharge unit and is designed to allow visual observation of the gas flow within the piping. When the injected gas passes through a leak point, bubbles are formed, which can be clearly identified within the valve structure. The present invention includes a transparent observation window that allows for precise observation of whether such bubbles are generated, thereby enhancing the accuracy of the diagnosis.

[0075] The bubble-type diagnostic unit is designed to be applicable to various gas types and piping conditions. It features an optimized structure that clearly reveals bubble formation not only in environments using light gases like natural gas but also in environments using heavier gases. This enables stable operation in diverse industrial settings and is effective for leak detection in large-diameter ball valves.

[0076] This device is designed for easy operation and maintenance. Operators can easily check for bubble formation through the observation window and quickly interpret diagnostic results. Furthermore, the bubble-based diagnostic unit is designed so that key components can be easily detached for cleaning or replacement. This extends the device's lifespan and enhances user work efficiency.

[0077] In this invention, high-quality materials were used to maximize the performance and durability of the bubble-type diagnostic unit. In particular, the observation window is made of a material resistant to impact and chemical damage, ensuring that its transparency is maintained even after prolonged use. This design enhances the reliability of large-diameter ball valve diagnosis while maximizing usability at the work site.

[0078] Specific configuration and role of the balloon diameter type diagnostic unit (150)

[0079] The balloon diameter type diagnostic unit (150) is a device used to detect abnormalities inside a large-diameter ball valve, and performs diagnosis by injecting gas to inflate the balloon and measuring the change in diameter. This method evaluates the sealing performance of the ball valve based on pressure changes within the piping and the condition of the balloon. In particular, it can precisely analyze the condition of a large-diameter ball valve with a complex internal structure.

[0080] This device is installed between the diagnostic gas injection unit and the discharge unit and inflates a specially manufactured balloon using gas. The balloon's inflation diameter reflects the internal space of the ball valve and the sealing state, thereby allowing for indirect verification of leakage. In this invention, a sensor is installed to precisely measure the balloon's inflation range, and the device is designed to detect even minute changes in diameter.

[0081] The balloon-diameter diagnostic unit allows for adjustment of the balloon material and size according to the operating environment, making it applicable to various ball valves and piping conditions. It utilizes highly durable materials that do not tear even in high-pressure environments and is manufactured to operate stably even in high-temperature or chemically corrosive conditions. This significantly enhances flexibility and reliability in industrial settings.

[0082] The operator can monitor the balloon's inflation status in real time and adjust the gas injection volume as needed. This prevents unnecessary gas waste and improves diagnostic efficiency. Additionally, it provides notifications when the balloon is fully inflated or exceeds a specific diameter, enabling the operator to take immediate action.

[0083] In this invention, the performance and maintenance convenience of the balloon-diameter type diagnostic unit are maximized. The balloon is designed for easy replacement, and a data output function linked to a sensor is added to record and analyze diagnostic results. This design makes the balloon-diameter type diagnostic unit an effective and highly reliable tool for evaluating the condition of large-diameter ball valves.

[0084] Specific configuration and role of the flow-type diagnostic unit (160)

[0085] The flow-type diagnostic unit (160) is a device that measures whether there is a leak and the extent thereof based on the gas flow inside a large-diameter ball valve, and is designed around an electronic flow meter. This diagnostic unit precisely measures the flow rate while the gas passes through the pipe, allowing for a quantitative evaluation of whether there is a leak. In particular, it is suitable for accurately diagnosing the condition of a large-diameter ball valve because it can detect minute changes in the flow rate.

[0086] The flow-type diagnostic unit includes an inspection outlet and an outlet valve mounted at specific locations in the piping, and is configured so that the gas flow passes through an electronic flow meter. The flow meter measures the velocity and volume of gas flow inside the piping in real time and outputs data. In this invention, the reliability of the diagnosis is enhanced by using a high-precision electronic flow meter, and the unit is designed to operate stably under various gas types and flow rate conditions.

[0087] This device is differentiated by its ability to quantitatively measure leaks that may occur during the diagnostic process. Changes in flow rate indirectly reflect internal damage or sealing defects within the ball valve, allowing for the analysis of the leak's location and extent. Furthermore, flow rate data can be utilized in conjunction with other diagnostic methods to enable a comprehensive assessment of the ball valve's condition.

[0088] Operators can monitor real-time data provided by the flow meter and immediately check for any abnormalities in gas flow. The flow-based diagnostic unit includes an automated warning system that provides notifications when flow rates exceeding or falling below set thresholds are detected. This enables operators to respond quickly and improves the efficiency of diagnostic operations.

[0089] In this invention, the durability and ease of use of the flow-type diagnostic unit have been maximized. The flow meter and valve are manufactured from durable materials capable of withstanding high-pressure and high-temperature environments, and are designed to facilitate maintenance. Furthermore, the addition of data recording and analysis functions allows for the storage of diagnostic results and the generation of reports as needed, making it useful for evaluating and managing the condition of large-diameter ball valves.

[0090] Specific structure and role of the output printer

[0091] The output printer is a device used to print diagnostic data in large-diameter ball valve complex diagnostic systems, documenting diagnostic results to enable operators to easily verify and record them. This printer collects data acquired through differential pressure, bubble, balloon diameter, and flow rate diagnostic units, processes it into a pre-set format, and outputs a diagnostic report. This enhances the reliability of diagnostic operations and allows for the systematic establishment of follow-up action plans.

[0092] The output printer operates in real-time connected to a diagnostic system to ensure data accuracy. Data is transmitted as digital signals, and the printer analyzes them to generate a comprehensive report. The report includes the results of each diagnostic method and an evaluation of any abnormalities, enabling the operator to clearly understand the diagnostic results. In this invention, an output method utilizing colors and charts is introduced to visually distinguish this data.

[0093] The printer was designed with mobility and durability in mind. It has been made compact and lightweight to suit the mobile structure of the diagnostic system, and features heat and impact resistance suitable for use in the diagnostic field. In addition, it combines economic efficiency and environmental friendliness by applying eco-printing technology that minimizes paper and ink consumption. This design contributes to the printer enhancing the efficiency of diagnostic operations and maximizing operational convenience.

[0094] Specific Structure and Role of Mobile Trolleys

[0095] The mobile trolley is a device designed to integrate and transport the key components of a large-diameter ball valve complex diagnostic system into a single unit. The diagnostic gas injection unit, diagnostic gas discharge unit, differential pressure diagnostic unit, bubble diagnostic unit, balloon diameter diagnostic unit, flow diagnostic unit, and output printer are mounted on the upper part, while wheels are installed on the lower part to allow for easy movement in the field. This trolley maximizes operational efficiency by integrating diagnostic equipment into a single system.

[0096] The trolley is constructed with a robust and durable structure, enabling stable operation even in diverse environments where large-diameter ball valves are installed. The bottom wheels can rotate and lock, ensuring stability during movement and stopping, while the trolley features a design that absorbs equipment vibrations and shocks to prevent damage. This allows the trolley to safely and efficiently transport equipment in various work environments.

[0097] In this invention, an easy-to-operate interface and storage space have been added to enhance the convenience of the mobile trolley. The trolley is equipped with a dedicated storage space for consumables and parts required for diagnosis, which the operator can access immediately as needed. Furthermore, each component of the trolley is designed for easy disassembly and assembly, making maintenance and management simple. These features contribute to increasing the efficiency and reliability of field operations.

[0098] Hereinafter, a diagnostic method using a large-diameter ball valve composite diagnostic system according to the present embodiment will be described in detail with reference to FIGS. 5 to 7.

[0099] The diagnostic method using a large-diameter ball valve complex diagnostic system according to the present embodiment includes a series of procedures for rapidly and accurately determining whether there is an abnormality in a ball valve in a large piping system. This diagnostic method consists of the steps of site visit, piping connection, execution of various diagnostic techniques, and residual gas discharge, and each step is efficiently carried out by utilizing diagnostic devices integrated within the system. The present invention focuses on systematizing this process to reduce work preparation time and increase the reliability of diagnostic results.

[0100] The diagnostic process begins by transporting the equipment to the site where the ball valve is installed using the diagnostic system's mobile trolley. Diagnostic gas injection units, diffusers, and differential pressure, bubble, balloon diameter, and flow rate diagnostic units mounted on the trolley are connected to the piping, and each diagnostic technique is performed sequentially. For example, the differential pressure diagnostic unit detects leaks by measuring pressure changes within the piping, the bubble diagnostic unit visually confirms bubbles generated in the event of a leak, and the flow rate diagnostic unit evaluates the extent of the leak by quantitatively analyzing the flow rate of the gas passing through the piping. All of these processes are recorded and analyzed in real time through an integrated data collection system.

[0101] Once the diagnosis is complete, residual gas inside the piping is safely vented to the outside through the venting unit. During this process, a silencer is utilized to suppress noise generated during venting and maintain a comfortable working environment. Finally, a report synthesizing the results of each diagnostic method is generated using a printer, supporting operators in clearly understanding the findings and planning necessary follow-up actions. This diagnostic method overcomes the inefficiency and complexity of existing technologies and provides a practical solution capable of quickly and accurately evaluating abnormalities in ball valves.

[0102] Field relocation phase

[0103] The field transport phase involves transporting diagnostic equipment to the work site where the ball valve is installed using a mobile trolley of the large-diameter ball valve complex diagnostic system. The mobile trolley is designed with a structure capable of integrating and mounting all diagnostic equipment, allowing for movement without the need for separate equipment disassembly or installation. This reduces work preparation time and increases efficiency during the transport process.

[0104] The trolley is constructed from highly durable materials, enabling stable movement even in harsh environments. The bottom wheels can rotate and lock, allowing operators to easily move the equipment and securely fix it at the work site. Additionally, the trolley is designed with a structure that absorbs vibrations and shocks, preventing damage to the equipment during transport.

[0105] The site movement phase is planned considering the accessibility of the work site. Even if the location where the ball valve is installed is narrow or difficult to access, the trolley can move flexibly due to its compact design. This effectively resolves the spatial constraints that occurred in existing equipment transport methods.

[0106] In this invention, a storage space is provided on the trolley to minimize problems that may occur during the movement process. The operator can store consumables and spare parts required for the diagnostic process on the trolley and use them immediately even while in motion. This significantly improves work efficiency at the site.

[0107] The site relocation phase holds significance beyond simple equipment movement. It is a crucial step that enables operators to inspect the equipment and environment in advance and prepare optimal working conditions. This ensures that the entire diagnostic process proceeds smoothly and safely.

[0108] High-pressure hose connection step

[0109] The high-pressure hose connection step is the process of connecting the large-diameter ball valve to the diagnostic system, enabling the diagnostic equipment to inject or release gas into the piping. The high-pressure hose connects the diagnostic gas injection and discharge sections to the piping, and each connection is designed with a robust sealed structure to prevent leakage.

[0110] The operator pre-inspects the connection status of the piping and hose before connecting the high-pressure hose. The length and diameter of the hose are adjusted to match the size of the large-diameter ball valve and the working environment, and the durability of the hose is guaranteed to maintain a stable connection even in high-pressure environments.

[0111] The hose connection is designed with an intuitive and simple procedure. In this invention, a Quick Connector is applied to the connection part to enable the operator to quickly and safely connect the high-pressure hose. This reduces connection time and increases work efficiency.

[0112] The stability of the connection is critical during the high-pressure hose connection stage. If the connection is unstable, gas leakage and work stoppage may occur. The present invention reinforces the connection to prevent leakage and includes a digital pressure gauge that allows the connection status to be checked in real time.

[0113] The connected high-pressure hose stably supplies or releases gas during diagnostic operations and can be easily disconnected after the work is completed. This simplifies the cleanup process after operation, reducing the burden on the operator and facilitating equipment maintenance.

[0114] Connection leak inspection stage

[0115] The connection leak inspection step involves checking the connection status between the piping and the hose after the high-pressure hose is connected to verify whether there is a gas leak. This step is essential to ensure operational safety and the reliability of the diagnostic results.

[0116] Leakage detection is performed using a leak indicator mounted on the connection. The leak indicator detects gas concentration around the connection in real time and provides visual and auditory warning signals in the event of a leak. This allows the operator to immediately identify the presence of a leak.

[0117] If a leak is detected, the operator reconnects the connection or replaces the problematic part. In this invention, the possibility of leakage is minimized by applying high-quality sealing materials and a robust locking mechanism to enhance the airtightness of the connection.

[0118] The connection leak inspection step serves to check the pressure status of the entire system in addition to verifying the presence of leaks. If abnormal pressure changes occur, problems other than those at the connections (e.g., pipe damage) may be suspected, in which case additional inspections are performed.

[0119] This step plays an important role in ensuring the initial safety of the diagnostic process. Once the connection leak test step is successfully completed, the diagnostic system is ready to operate stably, and subsequent diagnostic work can proceed smoothly.

[0120] Small-scale defense phase

[0121] The small-scale discharge step is a process of injecting a small amount of diagnostic gas into the large-diameter ball valve to be diagnosed, thereby initializing the system and creating a working environment. This step uses natural gas instead of greenhouse gases, and the amount of gas injected is limited to about 10% of that of existing technology, thereby achieving both resource conservation and environmental protection.

[0122] By injecting a small amount of gas, impurities within the piping are removed, and appropriate pressure conditions necessary for diagnosis are created. During this process, the strainer filters out foreign substances entering the piping, maintaining the cleanliness of the inside of the piping and increasing the reliability of the diagnosis results.

[0123] During the small-scale defense phase, gas pressure and inflow status are monitored in real time via digital pressure gauges. This data is used by operators to verify that the system is operating stably and to detect and resolve potential issues that may occur during the initialization process in advance.

[0124] In this invention, the safety of the working environment is enhanced through a small-scale radiation step. By reducing the risk factors associated with the existing high-pressure gas injection method and minimizing the amount of gas injected, both operational safety and efficiency are simultaneously ensured.

[0125] This stage serves as a preparatory step for the start of diagnostic work, providing a foundation to enhance the accuracy and reliability of various diagnostic methods (differential pressure, bubble, flow rate, etc.) to be performed later. This enables the diagnostic process to proceed more systematically and efficiently.

[0126] Differential pressure measurement stage

[0127] The differential pressure measurement step is a process that determines whether the ball valve is leaking by measuring the pressure difference inside the piping using a differential pressure diagnostic unit. This step evaluates sealing performance by detecting the pressure difference between two points within the piping, and allows for the confirmation of a leak through pressure changes.

[0128] The differential pressure gauge measures the pressure of the gas flow through the inlet and drain valves connected to both sides of the ball valve under diagnosis. The measured pressure data is provided digitally in real time, and the operator analyzes for leaks based on this data. In this invention, the differential pressure gauge is designed to enhance precision so that even minute pressure changes can be detected.

[0129] The operator monitors the data generated during the differential pressure measurement stage and evaluates for abnormalities by comparing it to a set reference pressure difference. If the differential pressure is abnormally high or low, it may be a signal indicating damage or leakage inside the ball valve. These results are analyzed in conjunction with other diagnostic stages to enable a more accurate diagnosis.

[0130] In this invention, a system for precisely controlling the gas injection amount and pressure is introduced to ensure the safety and efficiency of the differential pressure measurement stage. This prevents excessive pressure or system damage that may occur during the operation process.

[0131] The differential pressure measurement step is an important step for quantitatively evaluating the sealing status of large-diameter ball valves, contributing to increased reliability of diagnostic results and systematic planning of subsequent work.

[0132] Bubble measurement stage

[0133] The bubble measurement step is a process of visually verifying the presence of leaks within the piping using a bubble diagnostic unit. Abnormal conditions are determined by observing bubbles generated at the leak point as the diagnostic gas passes through the pipe. This is a simple yet intuitive method that allows for the clear identification of the leak location.

[0134] In this stage, the gas flow inside the piping passes through the observation window of the bubble diagnostic unit, and the operator checks for the occurrence of bubbles through this process. If bubbles are observed, it indicates a leak, and the location and amount of the bubbles can be visually evaluated.

[0135] In this invention, a high-sensitivity transparent observation window was used to improve the accuracy of the bubble measurement step. This observation window is made of a material resistant to chemical corrosion and impact, and clearly shows the gas flow and the shape of the bubbles.

[0136] The operator evaluates the degree of leakage by analyzing the size and frequency of bubbles. This process complements other diagnostic steps and helps to more accurately identify the location and cause of the leakage. Additionally, the present invention automates the bubble-based measurement step to add a function for recording and analyzing observation results.

[0137] The bubble measurement stage allows for the rapid verification of abnormalities in the ball valve, supporting on-site operator judgment and simultaneously enhancing the efficiency and reliability of the diagnostic process.

[0138] Flow rate measurement stage

[0139] The flow measurement stage is a process of quantitatively evaluating the presence of leaks by measuring the flow velocity and volume of gas within the pipeline through a flow diagnostic unit. It uses an electronic flow meter to precisely detect changes in gas flow, thereby indirectly confirming the location and amount of the leak.

[0140] In this stage, the diagnostic gas in the piping passes through the flow meter, and the flow meter records data in real time. In this invention, a high-precision electronic flow meter is adopted to detect even minute changes in flow rate, and it operates stably under various gas and flow rate conditions.

[0141] Flow rate data is utilized as critical information to enhance the reliability of diagnoses. Operators compare flow rate data with established reference values ​​to determine abnormalities, thereby evaluating the size and severity of leaks. Additionally, flow rate data is analyzed comprehensively with other diagnostic results to generate a comprehensive diagnostic report.

[0142] In this invention, an automatic data analysis and warning system is introduced to efficiently perform the flow rate measurement step. When a flow rate exceeding or falling below a set threshold is detected, a warning signal is output to enable the operator to take immediate action.

[0143] The flow measurement stage is an effective method for quantitatively analyzing the leakage status of ball valves, clarifying the results of diagnostic work and providing a basis for follow-up actions.

[0144] Residual gas release stage

[0145] The residual gas release phase is the process of safely venting gas remaining inside the piping to the outside after the diagnostic work is completed. This phase completely removes gas pressure within the piping after the work is finished, restoring the system to its original state and ensuring operational safety.

[0146] Residual gases are discharged to the outside through the exhaust unit, and a silencer is used during this process to minimize noise caused by gas emission. The silencer controls the velocity and pressure of the exhaust gases to maintain the comfort of the working environment and reduce operator fatigue.

[0147] The operator monitors the residual gas discharge status in real time and verifies whether the pressure within the piping has been completely removed. In this invention, the system is designed to accurately measure the pressure status during the discharge process using a digital pressure gauge and to confirm that all residual gas has been discharged.

[0148] The residual gas dissipation stage is designed to be environmentally friendly so that the emitted gas does not affect the working environment or the surroundings. This invention uses natural gas instead of greenhouse gases and minimizes emissions to reduce resource waste and environmental pollution.

[0149] This stage is an essential process for concluding the diagnostic work, restoring piping and equipment to a safe condition after completion and preparing the diagnostic system for maintenance and reuse. This maximizes the efficiency and safety of the diagnostic operation.

[0150] As examined above, the large-diameter ball valve combined diagnostic system of the present invention effectively solves the problems of inefficiency and lack of reliability that occurred in conventional technology. Previously, differential pressure, bubble, balloon diameter, and flow rate diagnostic methods were each performed by independent equipment, requiring operators to spend a significant amount of time managing multiple pieces of equipment and integrating data. The present invention integrates these four diagnostic methods into a single system to reduce operational complexity and maximize efficiency.

[0151] In conventional technology, data inconsistencies between devices frequently occurred, leading to a problem where the reliability of diagnostic results was low. The present invention collects all diagnostic data in real time and automatically analyzes it to ensure data integrity and accuracy. This enables operators to secure highly reliable diagnostic results and minimize additional verification processes.

[0152] Conventional technology using greenhouse gases in differential pressure diagnostic methods has been identified as one of the major causes of environmental pollution. The present invention uses natural gas as a diagnostic medium to replace greenhouse gases and is designed to use only about 10% of the gas compared to existing methods. Through this, atmospheric pollution is reduced, resource conservation is realized, and an eco-friendly diagnostic method is implemented.

[0153] The time wasted and physical inconvenience associated with the preparation process for diagnostic work have also been significantly improved by this invention. In conventional technology, installing and connecting individual pieces of equipment at the site required a considerable amount of time; however, this invention is designed to allow all equipment to be transported integrally via a mobile trolley and installed simply. This contributes to shortening work preparation time and reducing operator fatigue.

[0154] In conventional technology, it was difficult to analyze the causes of leaks from multiple perspectives due to the limitations of diagnostic methods. This invention integrates differential pressure, bubble, balloon diameter, and flow rate diagnostic methods into a single system, providing the capability to analyze the causes and locations of leaks from various angles. Through this, the abnormal condition of ball valves can be comprehensively evaluated, and maintenance plans can be systematically established.

[0155] The safety and convenience of the work site have also been significantly improved through this invention. This invention includes a connection leak inspection step and a small-scale discharge step to prevent safety issues that may occur during the diagnostic process, and enables real-time monitoring of the status through a digital pressure gauge and a leak indicator. These safety devices minimize risks to workers and ensure the safety of the diagnostic operation.

[0156] Finally, the present invention improves upon the limited data recording and management capabilities of the prior art. Data management and analysis are simplified by automatically generating a result report that aggregates data from each diagnostic method using an output printer. This supports the systematic recording of diagnostic results and the establishment of follow-up action plans, thereby enhancing overall operational productivity. Through these various effects, the present invention resolves the problems of the prior art and elevates efficiency and reliability in large-diameter ball valve diagnosis to a new level.

[0157] The above detailed description of the present invention describes only specific embodiments thereof. However, it should be understood that the present invention is not limited to the specific forms mentioned in the detailed description, but rather should be understood to include all variations, equivalents, and substitutions within the spirit and scope of the invention as defined by the appended claims.

[0158] In other words, the present invention is not limited to the specific embodiments and descriptions described above, and any person skilled in the art to which the present invention pertains can make various modifications without departing from the essence of the invention as claimed in the claims, and such modifications fall within the scope of protection of the present invention. Explanation of the symbols

[0159] 100: Large-diameter ball valve combined diagnostic system 110: Diagnostic gas injection unit 120: Diagnostic Gas Defense Division 130: Differential pressure diagnostic unit 140: Bubble-type diagnostic unit 150: Balloon diameter type diagnostic unit 160: Flow-type diagnostic unit

Claims

Claim 1 Connected to piping where a large-diameter ball valve subject to diagnosis with an inner diameter of 6 inches or more is installed, and introduces gas into the interior of the large-diameter ball valve subject to diagnosis. Diagnostic gas injection unit (110); It is a structure that communicates with the diagnostic gas injection unit (110) and exhausts the gas introduced into the large diameter ball valve to the outside under the control of the operator. Diagnostic gas radiation unit (120); It is mounted in a structure communicating with the piping where the large-diameter ball valve under diagnosis is installed, and is equipped with a differential pressure gauge inlet valve and a differential pressure gauge drain valve. Differential pressure diagnostic unit (130); A valve structure that is installed in a structure communicating between the diagnostic gas injection part (110) and the diagnostic gas discharge part (120) and is utilized in a bubble-type diagnostic method Bubble diagnostic unit (140); A valve structure that is mounted in a structure communicating between the diagnostic gas injection part (110) and the diagnostic gas discharge part (120) and is utilized in a balloon diameter type diagnostic method Balloon diameter type diagnostic unit (150); It is mounted in a structure communicating with the piping where a large-diameter ball valve subject to diagnosis is installed, and is equipped with an inspection outlet, an electronic flow meter, and an outlet valve. Flow rate diagnostic unit (160); Includes, and the above Diagnostic gas injection unit (110) The device is configured with a mesh-shaped filter to remove foreign substances before the diagnostic gas flows into the pipe, is integrated inside the diagnostic gas injection part (110), and has a structure that can be separated for cleaning or replacement to remove foreign substances accumulated in the filter. Strainer; Detects gas pressure within the piping system in real time and displays pressure data via a digital display. Digital pressure gauge; Detects changes in gas concentration within the piping system using high-sensitivity sensors and displays the detection data in real time. Leakage indicator; A leak determination output unit that, based on data obtained from a leak indicator, lights up a green lamp when the amount of gas leakage is low, changes to a yellow and red lamp as the amount of gas leakage increases, and simultaneously adjusts the volume or frequency of a warning sound; and Diagnostic gas defense department (120) It is mounted on one end of a pipe that exhausts gas introduced into a large-diameter ball valve to the outside, disperses the flow of the discharged gas using a porous material or internal baffle to reduce the velocity and energy of the gas, is formed of a special alloy or stainless steel that withstands high temperature and high pressure, and has a detachable structure to remove internal gas residue or foreign substances. muffle; Includes, and the above bubble diagnostic unit (140) The device includes a transparent observation window that allows visual confirmation of the flow of gas within the piping and bubbles generated by the gas, the observation window is formed to withstand impact and chemical damage, and is configured to determine the degree of leakage by observing whether bubbles are generated and the size and frequency of the bubbles. Balloon diameter type diagnostic unit (150) The device is configured to include a sensor that measures the expansion diameter of a balloon inflated by leaking gas, detect minute changes in the diameter of the balloon, monitor the balloon's expansion state in real time, and record and output balloon diameter measurement data in conjunction with the sensor, and the balloon is replaceably mounted, and the Flow rate diagnostic unit (160) It includes a high-precision electronic flow meter that measures and records the gas flow velocity and flow rate inside the pipe in real time, and is configured to determine whether there is an abnormality by comparing the measured flow rate with preset diagnostic criteria, and the above Differential pressure diagnostic unit (130) It is configured to classify the pressure change measured over 30 seconds under a diagnostic condition of 200 kPa as a micro leak when it is 20 kPa or more and 40 kPa or less, a small leak when it is 41 kPa or more and 80 kPa or less, and a small leak when it is 81 kPa or more. bubble diagnostic unit (140) It is configured to classify cases where bubbles occur intermittently as micro leakage, cases where bubbles occur continuously as trace leakage, and cases where the generated bubbles are too small to be counted with the naked eye as small leakage, and the above Flow rate diagnostic unit (160) It is configured to classify cases where the flow rate measured over 30 seconds is less than 0.009 m³ as micro leakage, cases where it is 0.009 m³ or more but less than 0.02 m³ as small leakage, and cases where it is 0.02 m³ or more as small leakage, and collects diagnostic result data obtained through a differential pressure diagnostic unit (130), a bubble diagnostic unit (140), a balloon diameter diagnostic unit (150), and a flow rate diagnostic unit (160) in real time, receives and synthesizes the data as digital signals, generates a result report including the results of each diagnostic method and an evaluation of abnormalities in a preset format, and outputs it using colors and charts. Printing press for output; A diagnostic gas injection unit (110), a diagnostic gas discharge unit (120), a differential pressure type diagnostic unit (130), a bubble type diagnostic unit (140), a balloon diameter type diagnostic unit (150), a flow rate type diagnostic unit (160), and an output printer are integrated and mounted on the upper part, and wheels that can rotate and be fixed are mounted on the lower part, absorbing vibrations and shocks transmitted to the diagnostic equipment during movement, and providing a storage space for storing consumables and parts required for diagnosis. Mobile trolley; Characterized by including Large-diameter ball valve complex diagnostic system. Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 Paragraph 1 A method for diagnosing the internal leakage condition of a large-diameter ball valve having an inner diameter of 6 inches or more using a large-diameter ball valve complex diagnostic system according to, wherein the mobile trolley of the large-diameter ball valve complex diagnostic system moves to the location where the large-diameter ball valve to be diagnosed is located Site transfer phase; Install piping in a structure communicating with the large-diameter ball valve to be diagnosed, install a high-pressure hose to inject diagnostic gas into the ball valve, and connect the high-pressure hose by applying a quick connector to the connection part of the high-pressure hose. High-pressure hose connection step; During the high-pressure hose connection stage, the gas concentration around the connection point is detected in real time using a leak indicator mounted on the connection point between the connected pipe and the high-pressure hose, and if a leak is detected, the connection point is reconnected or the problematic part is replaced to verify the connection status. Connection leak inspection step; Diagnostic gas is injected into the large-diameter ball valve under diagnosis through a high-pressure hose, foreign substances contained in the diagnostic gas are removed through a strainer, and the pressure and inflow status of the diagnostic gas are monitored in real time using a digital pressure gauge. Diagnostic gas injection step; A differential pressure diagnostic method is performed using a differential pressure gauge inlet valve and a differential pressure gauge drain valve installed in a structure communicating with the piping on which the large-diameter ball valve to be diagnosed is installed, wherein, under a diagnostic condition of 200 kPa, the pressure change measured over 30 seconds is classified as a minor leak if it is between 20 kPa and 40 kPa, a small leak if it is between 41 kPa and 80 kPa, and a small leak if it is 81 kPa or more. Differential pressure measurement stage; A bubble-type diagnostic method is performed using a valve and a transparent observation window of a bubble-type diagnostic unit (140) installed in a structure communicating between a diagnostic gas injection unit (110) and a diagnostic gas discharge unit (120), wherein cases where bubbles occur intermittently are classified as micro-leakage, cases where bubbles occur continuously are classified as micro-leakage, and cases where the generated bubbles are too small to be counted with the naked eye are classified as small-scale leakage. Bubble measurement stage; A balloon diameter type diagnostic unit (150) communicating between a diagnostic gas injection unit (110) and a diagnostic gas discharge unit (120) is used to inflate a balloon using leaked gas, and a sensor mounted on the balloon is used to measure the balloon's inflation diameter, monitor the balloon's inflation state in real time, and record the measured diameter data. Balloon diameter measurement step; A flow-based diagnostic method is performed using an inspection outlet, an electronic flow meter, and an outlet valve installed in a structure communicating with the piping where the large-diameter ball valve to be diagnosed is installed, wherein the flow rate measured over 30 seconds is classified as a minor leak if it is less than 0.009㎥, a small leak if it is 0.009㎥ or more but less than 0.02㎥, and a small leak if it is 0.02㎥ or more. Flow rate measurement step; Collecting and synthesizing diagnostic result data obtained through differential pressure measurement stage, bubble measurement stage, balloon diameter measurement stage, and flow rate measurement stage in real time, and generating and outputting a result report in a preset format that includes an evaluation of the results and abnormalities of each diagnostic method. Diagnosis result output step; Gas remaining inside the pipe communicating with the large diameter ball valve to be diagnosed is exhausted to the outside through the diagnostic gas discharge unit (120), while the flow of exhaust gas is dispersed and exhaust noise is reduced through a silencer, and the discharge state of the residual gas is checked by measuring the pressure inside the pipe through a digital pressure gauge. Residual gas release phase; Characterized by including Diagnostic method using a large-diameter ball valve complex diagnostic system.

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