In-Situ Vacuum-Pressure Valve Testing Without Tank Disassembly
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Solution Overview
Problem
Existing methods for testing vacuum/pressure relief valves are imprecise and require disassembly, leading to inefficiencies and potential damage, as they do not accurately assess valve behavior under operational conditions and require significant time and manpower.
Innovation Solution
A method that involves sealing the valve gastight on one side with a test valve, creating a test space, and applying an increasing pressure difference to measure the pressure at which the valve opens, allowing for in-situ testing without disassembly, using a test valve on the outside or inside of the valve housing to simulate operational conditions for both vacuum and pressure relief valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve housing is removed and examined on a test bench, then the valves can be tested for correct operation, but a lot of time and manpower is required and damage to the valves may occur
Solution Approach 1:
A test device is introduced as an intermediary component that connects between the valve housing and the storage tank. This test device includes a pressure chamber that can be pressurized independently, allowing the valve to be tested in its installed position without removing the valve housing from the tank, thereby eliminating the time-consuming disassembly and reassembly process while still enabling proper operational testing
Solution Approach 2:
The test device is prepared and positioned in advance before actual testing begins. The pressure chamber is pre-assembled and connected to the valve housing, allowing testing to start immediately without the need for time-consuming on-site assembly procedures. This preliminary preparation enables rapid testing while maintaining proper test conditions
2Reliability
If the valve housing is removed and examined on a test bench, then the valves can be tested for correct operation, but significant manpower is required
Solution Approach 1:
The test device serves as a simplified intermediary that replaces the complex test bench setup. By keeping the valve housing in its installed position and using the test device's pressure chamber to simulate operating conditions, the need for manual disassembly, transportation, and reassembly operations is eliminated, significantly reducing manpower requirements while maintaining testing effectiveness
Solution Approach 2:
The system is designed to be self-testing through the integrated pressure chamber that can be pressurized using the existing storage tank contents or a simple pump. This eliminates the need for external test benches and complex testing equipment, allowing a single operator to perform the testing procedure without requiring a team of workers
3Measurement precision
If mechanical force is applied to lift the plate, then the force required can be measured, but this does not measure the actual behavior under negative pressure or overpressure
Solution Approach 1:
Instead of using mechanical force application, the test device uses pneumatic pressure by introducing gas into the pressure chamber to simulate the actual operating conditions of negative pressure or overpressure. This allows the valve plate to respond naturally to pressure differential forces as it would during actual operation, providing accurate measurement of the opening pressure while preserving information about the valve's true operational behavior
Solution Approach 2:
The testing method changes from mechanical force application to pressure parameter control. By controlling the pressure in the test space and measuring the pressure at which the valve opens, the system directly measures the operational characteristic under realistic conditions, eliminating the need for force measurements and providing accurate information about the valve's actual behavior under pressure differentials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides accurate and efficient testing of vacuum and pressure relief valves under operational conditions, reducing the risk of failure and saving time and resources by allowing for direct on-site evaluation without disassembly, using a single overpressure or underpressure source to test both valves simultaneously.
Implementation Method 1
sealing at least a access from the environment to the vacuum valve gastight with a test valve, forming a test space between the test valve and the vacuum valve
Implementation Method 2
applying an increasing pressure difference between the test space and the valve housing, and measuring and recording the pressure in the test space until the valve is opened
Data Source
Figure 1~5
Figure 6~9
Figure 10~12
AI summary
The invention relates to a method for testing a vacuum/pressure valve (7, 8) in a valve housing (1) on a storage tank (4), comprising at least one of: I: - sealing an outside of a vacuum valve (7) gas-tight with a test valve (15), - applying an increasing overpressure in a test space (16) defined by the test valve and the vacuum valve that is higher than a pressure on the inside of the vacuum valve, and - measuring and recording the pressure in the test space until a valve of the vacuum valve is opened, and II: - sealing off a supply to the valve housing gastight, - applying an increasing overpressure in the valve housing that is higher than a pressure on the outside of the pressure valve, and - measuring and recording the pressure in the valve housing to a valve of the pressure relief valve is opened. Preference is given to a device for use in the method, comprising a pipe plug with pressure chamber for gastight placement in a flange connection to the vacuum valve, the device comprising a pressure gauge for measuring the pressure in the pressure chamber and a compressed gas connection for increasing the pressure in the pressure chamber.