CN113333409A - Full-automatic pigging and ball serving device and using method thereof - Google Patents
Full-automatic pigging and ball serving device and using method thereof Download PDFInfo
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- CN113333409A CN113333409A CN202110630729.7A CN202110630729A CN113333409A CN 113333409 A CN113333409 A CN 113333409A CN 202110630729 A CN202110630729 A CN 202110630729A CN 113333409 A CN113333409 A CN 113333409A
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- 238000000034 method Methods 0.000 title claims abstract description 22
- 230000007246 mechanism Effects 0.000 claims abstract description 61
- 238000004140 cleaning Methods 0.000 claims abstract description 39
- 239000007789 gas Substances 0.000 claims abstract description 27
- 230000005540 biological transmission Effects 0.000 claims abstract description 22
- 239000007788 liquid Substances 0.000 claims description 21
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 18
- 238000005260 corrosion Methods 0.000 claims description 16
- 230000007797 corrosion Effects 0.000 claims description 16
- 238000002347 injection Methods 0.000 claims description 14
- 239000007924 injection Substances 0.000 claims description 14
- 238000006073 displacement reaction Methods 0.000 claims description 13
- 239000003112 inhibitor Substances 0.000 claims description 13
- 239000003638 chemical reducing agent Substances 0.000 claims description 11
- 239000003345 natural gas Substances 0.000 claims description 9
- 239000010720 hydraulic oil Substances 0.000 claims description 8
- 239000013013 elastic material Substances 0.000 claims description 5
- 241000282887 Suidae Species 0.000 claims description 4
- 230000008569 process Effects 0.000 abstract description 13
- 239000002341 toxic gas Substances 0.000 abstract description 2
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000003921 oil Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000000047 product Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 229910000037 hydrogen sulfide Inorganic materials 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto
- B08B9/02—Cleaning pipes or tubes or systems of pipes or tubes
- B08B9/027—Cleaning the internal surfaces; Removal of blockages
- B08B9/04—Cleaning the internal surfaces; Removal of blockages using cleaning devices introduced into and moved along the pipes
- B08B9/053—Cleaning the internal surfaces; Removal of blockages using cleaning devices introduced into and moved along the pipes moved along the pipes by a fluid, e.g. by fluid pressure or by suction
- B08B9/057—Cleaning the internal surfaces; Removal of blockages using cleaning devices introduced into and moved along the pipes moved along the pipes by a fluid, e.g. by fluid pressure or by suction the cleaning devices being entrained discrete elements, e.g. balls, grinding elements, brushes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B13/00—Accessories or details of general applicability for machines or apparatus for cleaning
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Cleaning In General (AREA)
Abstract
The invention discloses a full-automatic pipe cleaning and ball serving device and a using method thereof, wherein the full-automatic pipe cleaning and ball serving device comprises a ball serving pipe section, a pipe cleaning ball valve B, an automatic ball changing mechanism and a hydraulic system which are sequentially connected; the service pipe section consists of a section of pipe with the same pipe diameter as the gas transmission pipe; the service pipe section is provided with one end connected with a gas transmission pipeline, and the other end of the service pipe section is connected with a pigging ball valve B; the ball serving pipe section is provided with a pressure sensor; the hydraulic system comprises a hydraulic cylinder; one end of the pigging ball valve B, which is far away from the ball serving pipe section, is connected with an automatic ball changing mechanism, and one end of the automatic ball changing mechanism, which is far away from the pigging ball valve B, is connected with a hydraulic cylinder; the device also comprises a PLC controller; the service pipe section, the pipe cleaning ball valve B, the automatic ball changing mechanism and the hydraulic system are all connected with the PLC through electric signals. The spherical pig pre-installing device is pre-installed with the spherical pig before operation, so that no manual participation is realized in the whole process in the operation process, and the working efficiency is improved; the safety accidents that people make mistakes and people are exposed in the toxic gas environment are avoided.
Description
Technical Field
The invention relates to the technical field of natural gas pipeline transportation, in particular to a full-automatic pipe cleaning and ball serving device and a using method thereof.
Background
In the long-distance transportation process of natural gas, due to the existence of impurities, moisture and the like, after the interior of the pipeline runs for a certain time, attached solid-phase and liquid-phase precipitates are generated in the pipeline, and at the moment, the pipeline is required to be cleaned regularly. The chemical corrosion of the pipeline caused by the pollutants, particularly the corrosion of untreated natural gas containing hydrogen sulfide to the inner wall of the pipeline is more serious, and the corrosion of the pipeline is delayed by regularly filling corrosion inhibitors into the pipeline in batches. The actual operation is performed using a ball receiving and sending device.
The prior ball serving device is arranged at the upstream end of a gas transmission pipeline, as shown in figure 1, a manual tool is used for loading a spherical pig into a barrel from a quick-opening blind plate of a ball serving barrel and then moving the spherical pig to a position with variable diameter of the ball serving barrel, a field operator replaces various valves on the device according to an operation flow to perform emptying and replacement, and pressure difference is established between the front and the back of the spherical pig to generate thrust to perform operations of cleaning pipes and filling corrosion inhibitors in batches, and the following problems exist in the operation process:
firstly, the quick-opening blind plate has a complex structure, and the accidental opening caused by misjudgment in the operation causes personnel safety accidents.
Secondly, the operation process is basically participated by manpower, and the labor intensity is high, the personnel demand is high, and the efficiency is low in the operation of the gas transmission pipeline pipe cleaning device with a large drift diameter.
And thirdly, when the spherical pig is manually moved to the large end and the small end of the serve barrel, the condition that the spherical pig fails to serve due to pressure difference failure caused by improper placement exists.
Fourthly, the operation steps are complicated, and the risk of manual misoperation exists.
And fifthly, when the conveying medium is natural gas with large sulfur content, the operation of opening the closed pipeline can expose operating personnel in a high-risk environment.
Disclosure of Invention
The invention aims to solve the technical problems that the existing ball serving device is basically used by manpower, the risk of manual misoperation and a plurality of potential safety hazards exist in the operation process, and the like, and aims to provide a full-automatic ball serving device for cleaning and managing, which solves the problems in the background technology.
The invention is realized by the following technical scheme:
a full-automatic pigging and ball serving device comprises a ball serving pipe section, a pigging ball valve B, an automatic ball changing mechanism and a hydraulic system which are connected in sequence;
the service pipe section consists of a section of pipe with the same pipe diameter as the gas transmission pipe; the service pipe section is provided with one end connected with a gas transmission pipeline, and the other end of the service pipe section is connected with a pigging ball valve B; the ball serving pipe section is provided with a pressure sensor; the ball serving pipe section is connected between the automatic ball changing device and the gas transmission pipeline, consists of various gates and a section of pipeline with the same diameter as the gas transmission pipeline, and comprises a pressure sensor; the service pipe section needs to be of a certain length so as to contain enough corrosion inhibitor and the like, so that the filling operation is convenient; the valves connected with the service pipe section can be controlled to be switched on and off by a PLC controller, the pressure value in the service pipe section cylinder is connected to the PLC by a pressure transmitter, the liquid injection ball valve of the service pipe section is connected with a liquid storage tank, liquid is injected by a liquid injection pump, and the information of the start and stop of the pump and the liquid injection amount is transmitted to the PLC controller;
the hydraulic system comprises a hydraulic cylinder; one end of the pigging ball valve B, which is far away from the service pipe section, is connected with an automatic ball changing mechanism, and one end of the automatic ball changing mechanism, which is far away from the pigging ball valve B, is connected with a hydraulic cylinder; the hydraulic system is connected with the automatic ball changing mechanism and is positioned at the tail end of the device, and the hydraulic system comprises a linear displacement sensor, a hydraulic rod, a hydraulic cylinder, a hydraulic oil pipe, a hydraulic control unit and the like; the hydraulic system is customized for a finished product, a hydraulic rod is required to be of three stages, the hydraulic rod can extend out to a sufficient length, and the spherical pig is pushed to a sufficient depth of a spherical pig launching pipe section; the hydraulic system is provided with a linear displacement sensor and transmits the information of the extension length of the hydraulic rod to the PLC; the hydraulic pump and the oil circuit switch are controlled by a PLC controller in an associated manner;
the automatic ball replacing mechanism comprises an outer bracket and an inner frame; a guide rail is arranged in the outer support and used for fixing an inner frame, and the inner frame can transversely translate on the guide rail; the inner frame is provided with a short pipe; the automatic ball changing mechanism is connected between the ball serving pipe section and the hydraulic system through a flange plate of the pipe cleaning ball valve B by bolts; the automatic ball changing mechanism comprises an outer support and an inner frame, the inner frame is provided with two short pipes which are slightly larger than the air conveying pipeline in clearing way, and the short pipes are provided with handles; the inner frame is fixed on the outer frame by a guide rail and can transversely translate under the drive of a motor; the short pipe can be taken down and placed into the short pipe, the ball cleaning pipe is placed in a groove in the device, the short pipe is driven by a motor and a gear to transversely translate on a track, one axis of the two short pipes is consistent with that of the ball serving cylinder, a position switch is used for detecting whether the movement is in place, then the short pipes are positioned through electromagnetic locks arranged on the edges of the outer support and the inner frame, and the ball serving pipe section, the short pipes of the inner frame and the hydraulic rod are in axial concentric positions;
the device also comprises a PLC controller; the ball serving pipe section, the pipe cleaning ball valve B, the automatic ball changing mechanism and the valve, the pressure and the operation machinery related to the hydraulic system are all connected with the PLC through electric signals to realize state and operation control.
The invention uses the hydraulic cylinder and the automatic ball changing mechanism to replace the original ball serving cylinder and the quick-opening blind plate. The original pigging device valve is additionally provided with an actuating mechanism, a part of emptying valves are replaced by electromagnetic valves, and the opening and closing of the emptying valves are automatically controlled by a PLC controller. A pressure sensor of a pipe cleaning device, a hydraulic rod extending displacement sensor, a position sensor and a magnetic force positioning device are additionally arranged, and a hydraulic cylinder is controlled by a PLC industrial automatic controller and is programmed with an industrial control program to realize the whole-course automatic operation. Changing a pigging and incoming air pipeline to the front end of a pigging ball valve B, directly sending a pigging ball into the pipeline during ball serving by using hydraulic power, and carrying out ball serving and other operations by using a pipe section between the pigging ball valve B and the pigging ball valve C at the front ends of openings of the pigging ball valve B and the pigging and incoming air pipeline; natural gas does not enter the automatic hydraulic ball changing mechanism and the hydraulic device, and relevant parts do not bear pressure; the automatic ball changing mechanism can fill 2 spherical pig (spherical pig A and spherical pig B) into the interior in advance, send out an instruction in a local or remote control room, or set an operation time period by the working state of a gas transmission pipeline, automatically start service and corrosion inhibitor filling, and transmit the working state to the control room in real time by a PLC (programmable logic controller) controller, so that the automatic unmanned operation of the whole process is realized, and the working efficiency and the operation safety are greatly improved.
Further, the external bolster includes an external bolster support plate; the outer support supporting plate is a hollow square frame consisting of a front baffle, a rear baffle, a lower supporting plate, a cover plate, a baffle and a supporting plate n-shaped fence; an outer support electromagnetic lock is arranged at the intersection of the support plate n-shaped fence and the baffle; the lower supporting plate is provided with a motor which is an explosion-proof motor;
the inner frame comprises an inner frame support plate and a short pipe; the inner frame supporting plate comprises a bottom plate, and a fixing frame for fixing the short pipe is arranged on the upper side of the bottom plate; a straight tooth plate is arranged in the middle of the lower side of the bottom plate; a guide rail guide block parallel to the straight tooth plate is arranged on the lower side of the bottom plate; the straight tooth plate is meshed with a gear of the explosion-proof motor; and electromagnetic locks matched with the electromagnetic locks of the outer bracket are arranged at the two ends of the fixing bracket.
Furthermore, the front baffle is provided with a front baffle round hole; the inner diameter of the round hole of the front baffle is larger than that of the gas pipeline; the outer side of the round hole of the front baffle is connected with a reducer of an automatic ball changing mechanism; one end of the large head and the small head of the automatic ball changing mechanism, which are far away from the round hole of the front baffle plate, is provided with a flange plate used for connecting a pigging ball valve B; the upper end of the big end and the small end of the automatic ball changing mechanism is provided with an exhaust hole.
Further, the rear baffle is provided with a rear baffle circular hole; two L-shaped parallel blocks are installed on the outer side of the rear baffle, and threaded holes used for connecting a hydraulic cylinder are formed in the end portions of the L-shaped parallel blocks.
Furthermore, a square hole is formed in the middle of the lower supporting plate, and an explosion-proof motor is mounted on the square hole; the left and the right of the lower supporting plate respectively extend to form two bottom fences for mounting guide rails; the left end part of the bottom fence is welded with the n-shaped fence of the supporting plate, and the right end part of the bottom fence is connected with the bottom end part of the n-shaped baffle through bolts.
Further, the cover plate is welded between the front baffle and the rear baffle and is positioned at the top of the outer support.
Further, a handle is arranged on the short pipe. The arrangement of the handle is convenient for taking out the short pipe.
Furthermore, a hydraulic rod is arranged in the hydraulic cylinder; the front end of the hydraulic rod is detachably provided with a hydraulic rod head; the top end of the hydraulic rod head is made of elastic materials. The front end of the hydraulic rod head is made of elastic materials and is connected with the hydraulic rod top through a screw thread, the hydraulic rod head is located between the hydraulic rod top and the spherical pig during working, the hydraulic rod head plays a role in protection, the corresponding hydraulic rod head can be replaced according to spherical pigs of different types, and when the hydraulic rod extends out, the hydraulic rod head penetrates through the hole of the spherical pig replacing mechanism and abuts against the spherical pig in the short tube to move forwards.
Further, the hydraulic system further comprises a linear displacement sensor, a hydraulic rod, a hydraulic oil pipe and a hydraulic control unit.
A use method of a full-automatic ball cleaning and serving device comprises the following steps:
s1: taking out the two short pipes in the inner frame, respectively filling the two short pipes with a spherical pig A and a spherical pig B, and then putting the two short pipes filled with the spherical pigs into the inner frame;
s2: checking and completely closing a pipe cleaning ball valve A, a pipe cleaning throttle valve, a pipe cleaning ball valve B, a liquid injection ball valve, a pipe cleaning ball valve C, a first vent valve, a second vent valve, a third vent valve, a fourth vent valve and a fifth vent valve;
s3: the motor rotates right to drive the inner frame to translate right to the rightmost end, and the right electromagnetic lock locks to position and fix the inner frame;
s4: fully opening the pipe cleaning ball valve B, and opening a fourth vent valve and a fifth vent valve;
s5: when the hydraulic system starts to operate, the hydraulic rod extends out of the hydraulic cylinder to drive the spherical pig A to move forwards and reach a spherical pig serving position A through the large head and the small head of the automatic spherical pig changing mechanism, the spherical pig B and the spherical pig serving pipe section; then the hydraulic rod returns to the original position;
s6: closing the fourth atmospheric valve and the fifth atmospheric valve;
s7: releasing the right electromagnetic lock, rotating the motor left to drive the inner frame to translate to the leftmost end leftwards, and locking the left electromagnetic lock to position and fix the inner frame;
s8: opening a third emptying valve, extending a hydraulic rod out of the hydraulic cylinder to drive the spherical pig B to move forwards and reach a spherical pig launching position B through a large head and a small head of the automatic spherical pig changing mechanism and the spherical pig B, and then returning the hydraulic rod to the original position;
s9: closing the pipe cleaning ball valve B, opening the liquid injection ball valve, and filling the corrosion inhibitor into the ball serving pipe section through the liquid injection ball valve;
s10: closing the liquid injection ball valve and the third emptying valve; opening a first emptying valve and a second emptying valve; a full-open pigging ball valve A and a micro-open pigging throttle valve are used for carrying out air replacement on the pipe section;
s11: after air replacement is carried out on the pipe section, the pipe cleaning throttle valve is fully opened; fully opening the pipe cleaning ball valve C and closing the outbound ball valve; pushing the spherical pig A, the corrosion inhibitor and the spherical pig B into the gas transmission pipeline by using natural gas, and then closing the spherical pig C;
s12: and opening the outbound ball valve, closing the pigging ball valve A and the pigging throttle valve, opening the first emptying valve and the second emptying valve, and closing the first emptying valve and the second emptying valve until the pressure of the ball serving pipe section is zero.
Compared with the prior art, the invention has the following advantages and beneficial effects:
the full-automatic pipe cleaning and ball serving device and the using method thereof simplify the structure and the operation steps of the ball serving device, avoid frequent operation of various valves in the operation processes of pipe cleaning, corrosion inhibitor filling and the like, and cancel a quick-opening blind plate. The invention greatly reduces the emptying operation in the operation process and is beneficial to green and environment-friendly production. The invention also avoids the ball-serving failure caused by the blockage at the large head and the small head when the spherical pig is pushed by the conveying medium during ball-serving, and improves the success rate of ball-serving during the operations of cleaning the pipe and filling. The spherical pig pre-installing device is pre-installed with the spherical pig before operation, so that no manual participation in the whole process can be realized in the operation process, and the working efficiency is improved; the safety accidents that people make mistakes and people are exposed in the toxic gas environment are avoided. At the present stage, a plurality of digital and automatic oil and gas fields are built on an initial scale, and the full-automatic pipe cleaning and ball serving device can be directly integrated into a platform. The invention realizes the automatic unmanned operation of the whole process and greatly improves the working efficiency and the operation safety.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a general plan view of a prior art pig serve device;
FIG. 2 is a general plan view of the pig serve device of the present invention;
FIG. 3 is a top right view of a three-dimensional structure of the automatic ball changing mechanism;
FIG. 4 is a lower right view of the three-dimensional structure of the automatic ball changing mechanism;
FIG. 5 is a three-dimensional structure diagram of an external support of the automatic ball replacing mechanism;
FIG. 6 is a three-dimensional structure diagram of an inner frame of the automatic ball changing mechanism;
fig. 7 is a partial enlarged view of the connection between the hydraulic cylinder and the automatic ball changing mechanism.
Reference numbers and corresponding part names in the drawings:
1-pigging ball valve A, 2-pigging throttle valve, 3-hydraulic cylinder, 31-hydraulic rod, 32-hydraulic rod head, 4-automatic ball changing mechanism, 5-pigging ball valve B, 6-liquid filling ball valve, 7-pigging ball valve C, 8-outlet ball valve, 91-first emptying valve, 92-second emptying valve, 93-third emptying valve, 94-fourth emptying valve, 95-fifth emptying valve, 96-sixth emptying valve, 97-seventh emptying valve, 98-eighth emptying valve, 99-ninth emptying valve, 10-quick-opening blind plate, 11-service position A, 12-service position B, 13-service ball, 14-hydraulic pipe connector, 15-emptying pipeline, 16-service ball barrel, 17-service ball barrel large-small-head, 41-an outer support, 42-an inner frame, 411-an outer support plate, 4111-a front baffle plate, 4112-a rear baffle plate, 4113-a lower supporting plate, 4114-a cover plate, 4115-a support plate n-shaped fence, 4116-a front baffle plate round hole, 4117-a rear baffle plate round hole, 4118-a bottom fence, 4119-a baffle plate, 412-an automatic ball changing mechanism reducer, 413-an n-shaped baffle plate, 414-a hydraulic cylinder connector, 415-an explosion-proof motor, 416-a guide rail, 417-a flange plate, 418-an outer support electromagnetic lock, 419-an exhaust hole, 421-a short pipe, 422-a lifting handle, 423-an inner frame electromagnetic lock, 424-a support plate, 425-a guide rail guide block and 426-a straight tooth plate.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to examples and accompanying drawings, and the exemplary embodiments and descriptions thereof are only used for explaining the present invention and are not meant to limit the present invention.
Examples
As shown in fig. 2, a full-automatic pigging and ball-serving device comprises a ball-serving pipe section 13, a pigging ball valve B5, an automatic ball-changing mechanism 4 and a hydraulic system which are connected in sequence;
the service pipe section 13 consists of a section of pipe with the same pipe diameter as the gas transmission pipe; the service pipe section 13 is provided with one end connected with a gas transmission pipeline, and the other end of the service pipe section 13 is connected with a pigging ball valve B5; the service pipe section 13 is positioned between the pigging ball valve 5 and the pigging ball valve 7, and the service pipe section 13 is connected with pigging natural gas incoming gas and various valves. The ball serving pipe section 13 is provided with a pressure sensor; the serve pipe section 13 is connected between the automatic ball changing mechanism 4 and the gas transmission pipeline, consists of various gates and a section of pipeline with the same diameter as the gas transmission pipeline, and comprises a pressure sensor; the service pipe section 13 needs to have a certain length so as to contain enough corrosion inhibitor and the like to facilitate filling operation; the valves connected with the service pipe section 13 can be controlled to be switched on and off by a PLC controller, the pressure value in the service pipe section 13 is connected to the PLC by a pressure transmitter, the liquid injection ball valve 6 on the service pipe section 13 is connected with a liquid storage tank, liquid is injected by a liquid injection pump, and the information of the start and stop of the pump and the liquid injection amount is transmitted to the PLC controller;
the hydraulic system comprises a hydraulic cylinder 3; one end of the pigging ball valve B5, which is far away from the ball serving pipe section 13, is connected with the automatic ball changing mechanism 4 through a flange plate at the large head and the small head, and one end of the automatic ball changing mechanism 4, which is far away from the pigging ball valve B5, is in threaded connection with the hydraulic cylinder 3; the hydraulic system is connected with the automatic ball changing mechanism 4 and is positioned at the tail end of the device, and the hydraulic system comprises a linear displacement sensor, a hydraulic rod, a hydraulic cylinder 3, a hydraulic oil pipe, a hydraulic control unit and the like; the hydraulic system is customized for a finished product, a hydraulic rod is required to be three-stage, the hydraulic rod can extend out for enough length, and the spherical pig is pushed to the enough depth of the spherical pig launching pipe section 13; the hydraulic system is provided with a linear displacement sensor and transmits the information of the extension length of the hydraulic rod to the PLC; the hydraulic pump and the oil circuit switch are controlled by a PLC controller in an associated manner;
the hydraulic system is finished product sleeving equipment and comprises an oil way control unit, a hydraulic cylinder 3, a hydraulic rod extending displacement sensor and a cable connected with the PLC for communication and control. Only the hydraulic cylinder 3 is shown in fig. 2, other facilities not being represented in the figure. The hydraulic cylinder 3 is covered and buckled with a hydraulic oil line pipeline, a hydraulic cylinder, a hydraulic rod extending displacement sensor and a hydraulic rod head.
As shown in fig. 3 and 4, the automatic ball changing mechanism 4 comprises an outer bracket 41 and an inner frame 42; as shown in fig. 5 and 6, a guide rail 416 is arranged in the outer bracket 41, the guide rail 416 is used for fixing the inner frame 42, and the inner frame 42 can transversely translate on the guide rail 416; the inner frame 42 is provided with a short pipe 421; the automatic ball changing mechanism 4 is connected between the ball serving pipe section 13 and a hydraulic system through a flange of the pipe cleaning ball valve B5 by bolts; the automatic ball changing mechanism 4 comprises an outer bracket 41 and an inner frame 42, wherein the inner frame 42 is provided with two short pipes 421 slightly larger than the gas transmission pipeline, and handles 422 are arranged on the short pipes 421; the inner frame 42 is fixed on the outer frame (outer frame 41) by a guide rail and can transversely translate under the drive of a motor; the short pipe 421 can be taken down and placed into the short pipe 421 and then placed in a groove in the device, and the short pipe is driven by the explosion-proof motor 415 and the gear to transversely translate on the track 416, so that the axis of one of the short pipes 421 is consistent with the axis of the service pipe section 13, a position switch is used for detecting whether the movement is in place, then the positioning is carried out through the electromagnetic locks arranged on the edges of the outer bracket 41 and the inner frame 42, and the service pipe section 13, the short pipe 421 of the inner frame 42 and the hydraulic rod are in axial concentric positions;
the device also comprises a PLC controller; the service pipe section 13, the pigging ball valve B5, the automatic ball changing mechanism 4 and the hydraulic system are all connected with the PLC through electric signals.
As shown in fig. 5, the outer support plate 411 of the outer support 41 of the automatic ball replacing mechanism 4 is a hollow square frame welded by steel plates, and is composed of a front baffle 4111, a rear baffle 4112, a lower support plate 4113, a cover plate 4114, a support plate pi-shaped fence 4115 and the like, and the sizes of the plate thickness, the length, the width and the like are determined by the pipe diameters of gas pipelines. The front baffle 4111 is provided with a front baffle round hole 4116 larger than the inner diameter of a gas transmission pipeline, the outer end of the front baffle round hole 4116 is welded with an automatic ball changing mechanism reducer 412, the other end of the automatic ball changing mechanism reducer 412 is welded with a flange 417, and the flange 417 is used for connecting a pigging ball valve 5; the inner diameter of the front end of the reducer 412 of the automatic ball changing mechanism is the same as that of the gas transmission pipeline, the inner diameter of the rear end of the reducer is the same as that of the inner frame short pipe, the upper end of the reducer is provided with an exhaust hole 419, and the air at the front end can be exhausted when the hydraulic rod pushes forwards by the spherical pig; the front baffle 4111 horizontally extends to the left and the right to form two fences, the right end part is provided with a screw hole, and the left side is welded with a supporting plate n-shaped fence 4115; the rear baffle 4112 is similar to the front baffle 4111 in shape, a rear baffle circular hole 4117 is formed in the middle, and the size of the rear baffle circular hole 4117 is determined by the size of the hydraulic rod head 32; the middle of the lower supporting plate 4113 is a square steel plate, a square hole is formed for installing the explosion-proof motor 415, the left side and the right side of the lower supporting plate 4113 respectively extend to form two fences for installing the guide rail 416, the left side of the fence is welded with the supporting plate n-shaped fence 4115, the right side end of the fence is provided with a screw hole, and the right side end of the fence is connected with the right side baffle 413 (the n-shaped baffle 413) through bolts, so that the inner frame can be conveniently assembled and disassembled; two L-shaped parallel blocks 414 are welded on the outer side of the rear baffle 4112, and threaded holes are formed in the end parts of the L-shaped parallel blocks 414 and are used for connecting the hydraulic cylinder 3 through bolts; an outer bracket electromagnetic lock electromagnetic block 418 is fixed at each intersection of the support plate n-shaped fence 4115 and the right baffle plate by screws; the cover plate 4114 is positioned at the top of the outer bracket 41, the cover plate 4114 is a steel plate slightly longer than the short pipe 421 and having a width similar to the outer diameter of the short pipe 421, and is welded between the front baffle 4111 and the rear baffle 4112, no fence is extended on the steel plate, and left and right spaces are left for the short pipe 421 to be taken out conveniently; position sensors are arranged at the left end and the right end of the lower supporting plate 4113, and when the inner frame moves to the positions of the two ends, a sensor trigger signal is sent to the PLC.
As shown in fig. 6, the supporting plate 424 of the inner frame 42 of the automatic ball changing mechanism is composed of a bottom plate, three vertical plates perpendicular to the bottom plate, and a semicircular pipe section welded on the vertical plates and having the same outer diameter as the short pipe, wherein the three vertical plates are parallel to each other and are provided with two semicircular openings. A toothed straight bar 426 is protruded below the bottom plate and meshed with a gear of an outer bracket explosion-proof motor 415, and when the motor rotates, six guide rail guide blocks 425 on the bottom plate are fixed on two guide rails 416 of the outer bracket to move; the two short pipes 421 are respectively arranged in the semicircular pipe sections, and can be taken out from the bracket through the handles 422 and loaded into the spherical pig; the inner frame bracket is shorter than the distance between the front baffle and the rear baffle of the outer frame, the short pipe 421 is slightly shorter than the distance between the front baffle and the rear baffle, when the inner frame bracket moves to the middle position, the lower half part is arranged in the semicircular pipe section, and a small gap is reserved between the top of the inner frame bracket and the outer frame cover plate 4114, so that the inner frame bracket is not blocked when moving and is not shaken when being stressed; two electromagnetic locks 423 are respectively arranged on the left side and the right side of the inner support through screws, the positions of the electromagnetic locks are corresponding to the positions of the magnetic blocks 418 of the outer support, namely when the inner frame moves to the left end position and the right end position, the two pairs of electromagnetic locks just contact.
As shown in figure 2, a service pipe section 13 is arranged between the pigging ball valve 5 and the pigging ball valve 7, one end of the service pipe section 13 close to the pigging ball valve 5 is communicated with a natural gas incoming pipeline, the air quantity is controlled by the throttle valve 2 to perform replacement and ball pushing operations, vent control valves are 91-95 on the service pipe section 13, and pressure is led out from the connection position of the third vent valve 93 and the gas pipeline to a transmitter so as to transmit a pressure signal to the PLC in real time.
As shown in fig. 7, a hydraulic rod 31 is provided in the hydraulic cylinder 3; a hydraulic rod head 32 is detachably mounted at the front end of the hydraulic rod 31; the top end of the hydraulic rod head 32 is made of elastic material. The front end of the hydraulic rod head 32 is made of elastic materials and is connected with the top of the hydraulic rod 31 through a screw thread, the hydraulic rod head is positioned between the hydraulic rod 31 and the spherical pig during working, the hydraulic rod head plays a role in protection, the corresponding hydraulic rod head 32 can be replaced according to spherical pigs of different types, and when the hydraulic rod 31 extends out, the hydraulic rod head penetrates through the hole of the automatic spherical pig replacing mechanism 4 and abuts against the spherical pig in the short pipe 421 to move forwards. The hydraulic cylinder 3 is connected to a hydraulic oil control unit through a hydraulic oil hose, the extension length of the hydraulic rod 31 is controlled, the extension length signal of the hydraulic rod 31 is transmitted into the PLC, and the working process is controlled by the PLC.
The hydraulic system further comprises a linear displacement sensor, a hydraulic rod, a hydraulic oil pipe and a hydraulic control unit.
The use method of the full-automatic pipe cleaning and ball serving device of the invention is explained by taking batch filling of corrosion inhibitor as an example: the inner frame 42 of the automatic ball changing mechanism 4 of the ball serving device is moved to a proper position, the left short pipe 421 and the right short pipe 421 are respectively taken out, the ball cleaners required by the operation are filled, and then the personnel leave the field. Starting a PLC industrial automatic operation program, namely checking whether the valves 1, 2, 5, 6, 7, 91-95 are in a closed state or not; whether the pressure of the service pipe section 13 is zero or not; whether the hydraulic lever is in a fully retracted state. The inner frame of the ball changing mechanism translates to the right on the track, when the ball changing mechanism moves to the rightmost end to trigger the position sensor to send a signal, the motor of the ball changing mechanism stops rotating, the electromagnetic lock on the right side of the mechanism is locked to position the inner frame, the hydraulic device mechanism starts to operate, the hydraulic rod extends out of the cylinder body to drive the cleaning ball A to move forwards to enter the large head 412 and the small head 412 to be close to the cleaning ball valve 5, the extension length of the linear displacement sensor of the hydraulic rod reaches a preset position, and the hydraulic rod stops extending out. The method comprises the following steps of-detecting whether the pressure of a ball serving barrel is reset to zero again, opening vent valves 96 and 97, fully opening a spherical pig valve 5, pushing a hydraulic rod forwards to enable the spherical pig to reach a ball serving position A11 shown in figure 2, enabling a PLC to detect that the extension distance is in place according to a hydraulic rod linear displacement sensor, stopping the extension of the hydraulic rod and starting retraction until the spherical pig is judged to be completely reset, closing vent valves 94 and 95, unlocking a right electromagnetic lock of an automatic ball replacing mechanism, enabling a motor to rotate left to drive an inner frame to translate leftwards on a track, and enabling the left position sensor to detect an in-place signal, stopping the rotation of the motor and enabling the left electromagnetic lock to work to position the inner frame. The emptying valve 93 is opened, the hydraulic rod extends out to drive the spherical pig B to move forwards, and the spherical pig B reaches the spherical pig delivery position B12 according to the judgment of the hydraulic rod linear displacement sensor. And the hydraulic rod stops extending and retracting until the hydraulic rod is judged to be completely returned, and the left electromagnetic lock is released. Closing the pipe cleaning ball valve 5, opening the liquid filling ball valve 6 and filling a sufficient amount of corrosion inhibitor into the ball serving pipe section. Closing the liquid filling ball valve 6, closing the emptying valve 93, opening the emptying valves 91 and 92, closing the full-open pigging ball valve A1, performing air replacement on the pipe section by the micro-open pigging throttle valve 2, then fully opening the pigging throttle valve 2, fully opening the pigging ball valve 7, closing the outbound ball valve 8, pushing the pigging ball and the corrosion inhibitor into the gas transmission pipeline, opening the outbound ball valve 8, closing the pigging ball valve A1 and the pigging throttle valve 2, closing the pigging throttle valve 2, opening the emptying valve 91 and the pigging throttle valve 2, and closing the emptying valve until the pressure of the ball sending pipe section 13 is zero.
The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are merely exemplary embodiments of the present invention, and are not intended to limit the scope of the present invention, and any modifications, equivalent substitutions, improvements and the like made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A full-automatic pigging and ball-serving device is characterized by comprising a ball-serving pipe section (13), a pigging ball valve B (5), an automatic ball-changing mechanism (4) and a hydraulic system which are sequentially connected;
the service pipe section (13) consists of a section of pipe with the same pipe diameter as the gas transmission pipe; the service pipe section (13) is provided with one end connected with a gas transmission pipeline, and the other end of the service pipe section (13) is connected with a pigging ball valve B (5); the ball serving pipe section (13) is provided with a pressure sensor;
the hydraulic system comprises a hydraulic cylinder (3); one end, far away from the ball serving pipe section (13), of the pigging ball valve B (5) is connected with an automatic ball changing mechanism (4), and one end, far away from the pigging ball valve B (5), of the automatic ball changing mechanism (4) is connected with a hydraulic cylinder (3);
the automatic ball changing mechanism (4) comprises an outer bracket (41) and an inner frame (42); a guide rail (416) is arranged in the outer support (41), the guide rail (416) is used for fixing the inner frame (42), and the inner frame (42) can transversely translate on the guide rail (416); a short pipe (421) is arranged on the inner frame (42);
the device also comprises a PLC controller; the ball serving pipe section (13), the pipe cleaning ball valve B (5), the automatic ball changing mechanism (4) and valves, pressure and operation machinery related to a hydraulic system are all connected with the PLC through electric signals to realize state and operation control.
2. The full-automatic pigging and ball-serving device according to claim 1,
the outer bracket (41) includes an outer bracket support plate (411); the outer support supporting plate (411) is a hollow square frame consisting of a front baffle plate (4111), a rear baffle plate (4112), a lower supporting plate (4113), a cover plate (4114), a baffle plate (4119) and a supporting plate n-shaped fence (4115); an outer bracket electromagnetic lock (418) is arranged at the intersection of the support plate n-shaped fence (4115) and the baffle plate (4119); a motor is installed on the lower supporting plate (4113), and the motor is an explosion-proof motor (415);
the inner frame (42) comprises an inner frame support plate (424) and a short pipe (421); the inner frame supporting plate (424) comprises a bottom plate, and a fixing frame for fixing the short pipe (421) is arranged on the upper side of the bottom plate; a straight tooth plate (426) is arranged in the middle of the lower side of the bottom plate; a guide rail guide block (425) parallel to the straight tooth plate (426) is arranged on the lower side of the bottom plate; the straight tooth plate (426) is meshed with a gear of the explosion-proof motor (415); electromagnetic locks (423) matched with the electromagnetic locks (418) of the outer bracket are arranged at the two ends of the fixing bracket.
3. The full-automatic pigging and serving device according to claim 2, wherein the front baffle (4111) is provided with a front baffle circular hole (4116); the inner diameter of the front baffle circular hole (4116) is larger than the inner diameter of the gas transmission pipeline; the outer side of the front baffle circular hole (4116) is connected with a reducer (412) of an automatic ball changing mechanism; one end, far away from the round hole (4116) of the front baffle, of the large head (412) of the automatic ball changing mechanism is provided with a flange (417) used for connecting a pigging ball valve B (5); an exhaust hole (419) is formed in the upper end of the reducer head (412) of the automatic ball changing mechanism.
4. The full-automatic pigging and serving device according to claim 2, wherein the rear baffle (4112) is provided with a rear baffle circular hole (4117); two L-shaped parallel blocks (414) are installed on the outer side of the rear baffle (4112), and threaded holes for connecting the hydraulic cylinders (3) are formed in the end parts of the L-shaped parallel blocks (414).
5. The full-automatic pigging and ball-serving device according to claim 2, characterized in that a square hole is opened in the middle of the lower supporting plate (4113), and an explosion-proof motor (415) is installed on the square hole; the lower supporting plate (4113) extends leftwards and rightwards to form two bottom fences (4118) for mounting a guide rail (416); the left end of the bottom rail (4118) is welded with a support plate n-shaped rail (4115), and the right end of the bottom rail (4118) is in bolt connection with the bottom end of the n-shaped baffle (413).
6. The full-automatic pigging and pitching device according to claim 2, wherein said cover plate (4114) is welded between the front baffle plate (4111) and the rear baffle plate (4112) at the top of the external frame (41).
7. The fully automatic pigging and serving device according to claim 2, characterized in that said short tube (421) is provided with a handle.
8. The full-automatic pigging and serving device according to claim 2, characterized in that a hydraulic rod (31) is arranged in the hydraulic cylinder (3); a hydraulic rod head (32) is detachably mounted at the front end of the hydraulic rod (31); the top end of the hydraulic rod head (32) is made of elastic materials.
9. The full-automatic pigging and ball-serving device according to claim 2, wherein the hydraulic system further comprises a linear displacement sensor, a hydraulic rod, a hydraulic oil pipe and a hydraulic control unit.
10. The use method of the full-automatic ball cleaning and serving device is characterized by comprising the following steps:
s1: taking out two short pipes (421) in the inner frame (42), respectively filling the two short pipes (421) with a spherical pig A and a spherical pig B, and then putting the two short pipes (421) filled with the spherical pigs into the inner frame (42);
s2: inspecting and completely closing a pipe cleaning ball valve A (1), a pipe cleaning throttle valve (2), a pipe cleaning ball valve B (5), a liquid injection ball valve (6), a pipe cleaning ball valve C (7), a first emptying valve (91), a second emptying valve (92), a third emptying valve (93), a fourth emptying valve (94) and a fifth emptying valve (95);
s3: the motor rotates right to drive the inner frame (42) to translate right to the rightmost end, and the right electromagnetic lock locks to position and fix the inner frame;
s4: fully opening a pigging ball valve B (5), and opening a fourth emptying valve (94) and a fifth emptying valve (95);
s5: when the hydraulic system starts to operate, the hydraulic rod (31) extends out of the hydraulic cylinder (3) to drive the spherical pig A to move forwards and reach a spherical pig serving position A (11) through the reducer (412) of the automatic ball changing mechanism, the spherical pig B (5) and the spherical pig serving pipe section (13); then the hydraulic rod (31) returns to the original position;
s6: closing the fourth vent valve (94) and the fifth vent valve (95);
s7: the right electromagnetic lock is released, the motor rotates left to drive the inner frame (42) to translate leftwards to the leftmost end, and the left electromagnetic lock locks and positions and fixes the inner frame;
s8: opening a third emptying valve (93), extending a hydraulic rod (31) out of a hydraulic cylinder (3) to drive a spherical pig B to move forwards and reach a spherical pig launching position B (12) through a reducer (412) of an automatic spherical pig changing mechanism and a spherical pig B (5), and then returning the hydraulic rod (31) to the original position;
s9: closing the pipe cleaning ball valve B (5), opening the liquid injection ball valve (6), and filling the corrosion inhibitor into the ball serving pipe section (13) through the liquid injection ball valve (6);
s10: closing the liquid injection ball valve (6) and the third emptying valve (93); opening a first vent valve (91) and a second vent valve (92); the full-open pigging ball valve A (1) and the micro-open pigging throttle valve (2) perform air replacement on the pipe section;
s11: after air replacement is carried out on the pipe section, the pipe cleaning throttle valve (2) is fully opened; fully opening a pipe cleaning ball valve C (7) and closing an outbound ball valve (8); pushing the spherical pig A, the corrosion inhibitor and the spherical pig B into the gas transmission pipeline by using natural gas, and then closing the spherical pig C (7);
s12: and (2) opening an outbound ball valve (8), closing a pigging ball valve A (1) and a pigging throttle valve (2), opening a first emptying valve (91) and a second emptying valve (92), and closing the first emptying valve (91) and the second emptying valve (92) until the pressure of a ball serving pipe section (13) is zero.
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| CN202110630729.7A CN113333409B (en) | 2021-06-07 | 2021-06-07 | Full-automatic pigging and ball serving device and using method thereof |
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| CN202110630729.7A CN113333409B (en) | 2021-06-07 | 2021-06-07 | Full-automatic pigging and ball serving device and using method thereof |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113847822A (en) * | 2021-09-26 | 2021-12-28 | 上海铎点环保科技有限公司 | Full-automatic coke cleaning device for U-shaped furnace pipe of petrochemical manifold |
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