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Factory workshop valve leakage detection service online non-destructive leak detection
NegotiableUpdate on 05/14
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Overview
Factory workshop valve leakage detection service online non-destructive leak detection $r $n Industry: precise detection of high temperature and high pressure systems. The steam system of a chemical enterprise operates at a pressure of 16 bar and a temperature of 350 ℃. The drain valve has been under high temperature and high pressure conditions for a long time, and the aging and corrosion of seals are prominent, resulting in frequent leakage failures. Traditional manual auscultation is difficult to detect small leaks due to environmental noise interference, resulting in serious steam waste and high annual energy consumption costs. After applying LE4800plus ZS, technicians quickly completed the detection of 120 drain valves in the entire system and identified 18 of them within 3 hours
Product Details
Factory workshop valve leakage detection service online non-destructive leak detection
Factory workshop valve leakage detection service online non-destructive leak detection
1. Chemical industry: case study of precise detection of high temperature and high pressure systems
The production conditions of chemical industry are harsh, and many steam systems are in long-term operation16bar high pressure, 350 ℃ high temperatureOperating environment. The long-term operation of the drain valve in the system under high temperature and high pressure loads is prone to problems such as aging of seals and corrosion of valve bodies, resulting in frequent valve leaks. The on-site noise in the workshop is complex, and the traditional manual auscultation method is greatly affected by environmental interference. Small leaks cannot be accurately identified, and long-term hidden leaks cause a large amount of steam loss. The energy consumption cost of the enterprise is increasing year by year.
Enterprise IntroductionLE4800plus ZS sonar infrared drain valve detectorSystematic testing was carried out, and technicians efficiently completed a comprehensive inspection of 120 drain valves in the entire factory. In just 3 hours, 18 devices with potential leakage hazards were accurately screened, including 5 with severe leakage, with a leakage rate of over 50kg/h. Relying on equipment quantitative testing data, enterprises can accurately locate the root cause of faults, customize rectification plans, and centrally replace core components such as aging seals and damaged valve cores.
After the rectification is completed, the steam loss can be reduced by 3.2 tons per month,Annual energy-saving income exceeds 150000 yuanAt the same time, relying on detection data, establish a health record for the entire life cycle of steam traps, implement a quarterly regular inspection mechanism, achieve early prediction and control of faults, and prevent valve leakage faults from recurring within six months after rectification, effectively ensuring the safe, stable, energy-saving and efficient operation of high-temperature and high-pressure steam systems.
2. Textile industry: Efficient investigation and treatment cases of multiple types of drain valves
The layout of steam pipelines in textile enterprises is complex, with more than 200 types of steam traps including floating ball type, thermal static type, and inverted bucket type installed on site. Due to the complexity of equipment models and significant structural differences, traditional testing requires classification and adaptation of testing methods. The inspection process is cumbersome, the efficiency of operations is low, and hidden faults such as blockage and internal leakage are easily overlooked. After the blockage and failure of the drain valve, it directly leads to a decrease in the heating efficiency of the heat exchange equipment, unstable temperature in the workshop drying process, frequent color difference and defects in the finished fabric, and seriously restricts the product yield rate.
Adopting LE4800plus ZS integrated detection equipment, the instrument is equipped with a full range of drain valve compatible detection templates, eliminating the need to distinguish equipment models and achievingNo classification required, instant testing upon alignmentSignificantly simplifying the detection process. In just 2 days, we completed a comprehensive inspection of over 200 drain valves in the entire factory, accurately identifying 32 devices with blockage faults, including 12 severe blockage points.
Customize differentiated treatment plans for different types of equipment failure characteristics: the floating ball drain valve uses high-pressure impurity flushing to clean blockages, and the thermal static drain valve replaces aging valve core accessories to quickly restore equipment drainage and exhaust performance. After the renovation, the operating efficiency of the workshop heat exchange equipment increased by 12%, the uniformity of fabric drying significantly improved, and the product qualification rate increased from 88% to 98%; At the same time, simplify the inspection process, reduce manual operation and maintenance costs by 60%, and balance production quality improvement and operation and maintenance cost control.
3. Food processing industry: Health grade non-destructive testing balances compliance and energy efficiency
The production standards in the food processing industry are strict, and the steam system is directly related to core processes such as food heating, fermentation, and sterilization, with high requirements for equipment hygiene level and production safety. Leakage and blockage of drain valves not only cause waste of steam energy consumption and imbalance of heating temperature, but also easily lead to the reflux of condensed water into production tanks, causing material pollution, batch product scrapping, and serious production losses. The traditional contact detection method has the risk of cross contamination, cannot adapt to the hygiene control requirements of food workshops, and has insufficient detection accuracy, making it difficult to detect minor faults.
The enterprise uses the LE4800plus ZS drain valve detector, relying onSonar+infrared dual-mode non-contact detectionAdvantages: No equipment contact or secondary pollution throughout the entire process, in line with the hygiene production standards of the food industry. The instrument can quickly and accurately identify various faults such as leakage, blockage, and poor drainage in the drain valve, and avoid potential production hazards such as condensate accumulation and uneven temperature in advance.It was found on site that there was a slight blockage in the drain valve of the heating tank. After timely cleaning and unblocking, the temperature of the tank was restored to balance, ensuring the stability of the fermentation process and effectively avoiding large-scale material scrap losses.
Through normalized precise detection and data-driven energy consumption analysis, the enterprise has established a standardized equipment maintenance system, optimized the steam system operation and maintenance plan, and reduced steam energy consumption by 8% throughout the year. It not only meets the requirements of food safety production compliance, eliminates hygiene risks, but also achieves energy consumption reduction and cost saving, achieving multiple goals of safety production, quality control, and energy conservation and cost reduction.
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