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CN-117803863-B - Corrosion monitoring system and method based on fixed-point thickness measurement

CN117803863BCN 117803863 BCN117803863 BCN 117803863BCN-117803863-B

Abstract

The invention discloses a corrosion monitoring system and method based on fixed-point thickness measurement. According to the method, basic information of a device to be monitored is stored in a fixed-point thickness measurement corrosion monitoring processing center, equipment standing accounts and two-dimensional codes are generated, the two-dimensional codes are attached to the device to be monitored, measurement points of the device to be monitored and initial measurement frequency are determined to form an initial thickness measurement monitoring plan, the thickness measurement standing accounts of all measurement points are generated by the fixed-point thickness measurement corrosion monitoring processing center, according to the initial thickness measurement monitoring plan of the measurement points, wall thicknesses of the measurement points are measured on time by using an intelligent mobile terminal and stored in the fixed-point thickness measurement corrosion monitoring processing center, monitoring grades of the measurement points are divided after calculation, the thickness measurement frequency is determined again according to the monitoring grades, and corrosion monitoring early warning is carried out. According to the invention, the monitoring level of the measurement point positions is divided by multiple parameters, the thickness measurement plan and the corrosion risk early warning are updated, the integrated management of the corrosion monitoring detection data of the equipment is realized, and the safe operation of the device is ensured.

Inventors

  • HAN LEI
  • ZHANG YANLING
  • CHAI YONGXIN
  • QU DINGRONG

Assignees

  • 中国石油化工股份有限公司
  • 中石化安全工程研究院有限公司

Dates

Publication Date
20260508
Application Date
20220930

Claims (13)

  1. 1. The corrosion monitoring method based on the fixed-point thickness measurement is characterized by adopting a corrosion monitoring system based on the fixed-point thickness measurement, wherein the corrosion monitoring system based on the fixed-point thickness measurement comprises a fixed-point thickness measurement corrosion monitoring processing center and an intelligent mobile terminal; The fixed-point thickness measurement corrosion monitoring processing center is used for measuring the thickness of the basic information and the measurement point of the device to be monitored of the reservoir, generating the two-dimensional code of the device to be monitored, acquiring the thickness measurement data of the intelligent mobile terminal in real time, and analyzing and evaluating the measurement point; the intelligent mobile terminal is provided with a display, a code scanner, a thickness meter and a control center, wherein the display is used for displaying information of measurement points with the monitoring grade of A on a device to be monitored, the code scanner is used for scanning two-dimensional codes on the device to be monitored to obtain basic information of the device to be monitored, and the thickness meter is used for measuring the thickness of a wall body of each measurement point on the device to be monitored and transmitting and storing the thickness information to the fixed-point thickness measurement corrosion monitoring processing center in real time; The display, the code scanner and the thickness gauge are respectively connected with the control center, and the intelligent mobile terminal is in communication connection with the fixed-point thickness measurement corrosion monitoring processing center; The method is suitable for refining equipment and pipelines, and specifically comprises the following steps of: step 1, basic information of a device to be monitored is obtained and stored in a fixed-point thickness measurement corrosion monitoring processing center, and an equipment ledger of the device to be monitored is generated; step 2, generating a two-dimensional code of the device to be monitored by using a fixed-point thickness measurement corrosion monitoring processing center, and attaching the two-dimensional code to the device to be monitored; Step 3, selecting a plurality of measurement points for measuring thickness on a device to be monitored, determining initial measurement frequency of each measurement point, respectively making an initial thickness measurement monitoring plan for each measurement point, recording each set measurement point in basic information stored in a fixed-point thickness measurement corrosion monitoring processing center, and generating a thickness measurement ledger of each measurement point by using the fixed-point thickness measurement corrosion monitoring processing center; step 4, according to an initial thickness measurement monitoring plan of each measurement point, measuring the wall thickness of the measurement point on time by using an intelligent mobile terminal, transmitting the wall thickness to a fixed-point thickness measurement corrosion monitoring processing center, correspondingly storing the wall thickness measured by each measurement point in a thickness measurement ledger of each measurement point, and updating the thickness measurement ledger of each measurement point; Step 5, after the initial thickness measurement monitoring of the device to be monitored is completed according to the initial thickness measurement monitoring plan of each measurement point, the thickness measurement ledger of each measurement point is called by the fixed-point thickness measurement corrosion monitoring processing center, and the monitoring grade of each measurement point is respectively determined, and the method specifically comprises the following steps: Step 5.1, obtaining a thickness measuring ledger of each measuring point by using a fixed-point thickness measuring corrosion monitoring processing center, and determining the wall thickness obtained at each measuring moment of the measuring point; Step 5.2, respectively calculating absolute thinning amounts of all the measurement points Relative thinning amount Total thinning rate And remaining life ; Absolute thinning of measuring point The calculation formula is as follows: (1) in the formula, To measure the wall thickness at point 1 st measurement, Wall thickness at the Nth measurement of the measurement point; Relative thinning of measuring point The calculation formula is as follows: (2) Total thinning rate of measurement point The calculation formula is as follows: (3) In the formula (3), A first calculation factor for the total thinning rate, A second calculation factor for the total thinning rate, To measure the thinning rate at the nth measurement of the spot, The thinning rate is integrated and averaged for the measurement point, wherein the thinning rate of the measurement point in the Nth measurement is reduced As shown in formula (4), the integrated average thinning rate of the measurement point position As shown in formula (5): (4) (5) in the formula, The thickness of the wall body is measured for the N-1 th time of the measuring point; to measure the time of the nth measurement of a spot, To measure the time of the N-1 th measurement of a spot, To measure the time of the nth measurement of a spot, Thinning speed in ith measurement of the measurement point; measuring the remaining life of a point location The calculation formula is as follows: (6) in the formula, The minimum bearing wall thickness of the device to be measured; Step 5.3, respectively aiming at each measuring point, according to the absolute thinning amount WT and the relative thinning amount of each measuring point Total thinning rate And remaining life Dividing the monitoring level of each measuring point; If the relative thinning of the measuring point is measured Less than or equal to 20 percent and the total thinning rate Less than or equal to 0.1mm/a and the residual life The monitoring grade of the measurement point location is divided into C grade if the measurement point location meets the relative thinning amount 40% And total thinning rate Any one of >0.3mm/a and absolute thinning amount WT >1mm, or the measurement point satisfies the remaining life The monitoring grade of the measurement point location is classified into a grade A after 1.5 years; removing the condition that the monitoring level is divided into a level A and a level C, and dividing the monitoring level of the measurement point into a level B in the rest conditions; Step 6, according to the monitoring grade of each measuring point, the thickness measuring frequency of each measuring point is redetermined, and the thickness measuring ledger of each measuring point is updated; and 7, utilizing a fixed-point thickness measurement corrosion monitoring processing center to retrieve and update the thickness measurement ledger of each measurement point, pushing the thickness measurement ledger of the measurement point with the monitoring grade of A to the intelligent mobile terminal, and analyzing each measurement point with the monitoring grade of A and formulating anti-corrosion measures by professional technicians according to the thickness measurement ledger of the measurement point checked by the intelligent mobile terminal.
  2. 2. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 1, if the device to be monitored is a refining device, the obtained basic information comprises a single equipment diagram and an equipment ledger of the refining device, and if the device to be monitored is a pipeline, the obtained basic information comprises a single line diagram and a pipeline ledger of the pipeline.
  3. 3. The corrosion monitoring method based on fixed point thickness measurement according to claim 2, wherein the number, name, starting point, end point, material, internal flow medium, design temperature, design pressure, operating temperature, operating pressure, pipe length, number of welds, number of bends, anti-corrosion heat-insulating material, pressure level, safety level, equipment importance level, time of use, maintenance record and manufacturing unit of the pipe are recorded in an equipment ledger of the pipe.
  4. 4. The corrosion monitoring method based on fixed-point thickness measurement according to claim 2, wherein when the refining equipment is furnace equipment, the name of a furnace body, a process number, an internal medium, equipment specifications, a heat load, design pressure, design temperature, outlet pressure, outlet temperature, inlet pressure, inlet temperature, furnace tube materials, furnace tube specifications, radiation furnace tube number, convection furnace tube number, elbow type, elbow number, elbow material, highest temperature in a hearth, flue temperature, burner number and model, heat preservation form, equipment importance level, service time, maintenance record and manufacturing unit are recorded in an equipment ledger; When the refining equipment is tower equipment, the name, the process number, the specification, the material, the tray structural parameters, the size and the material of a tower top cover, the size and the material of a tower bottom cover, the design temperature and the design pressure of the top of the tower, the design temperature and the design pressure of the bottom of the tower, the operation pressure and the operation temperature of the top of the tower, the operation pressure and the operation temperature of the bottom of the tower, the importance level of the equipment, the time of use, the maintenance record and the manufacturing unit are recorded in an equipment ledger; When the refining equipment is container equipment, the names, process numbers, memory media, specifications, materials, design temperature and pressure, operation temperature and operation pressure, anti-corrosion heat-insulating materials, equipment importance level, service time, maintenance records and manufacturing units of the containers are recorded in the equipment ledger; When the refining equipment is heat exchange equipment, the name, model, process number, material, tube plate size of a tube bundle, internal medium, tube side design pressure and design temperature, shell side design pressure and design temperature, tube side operation pressure and operation temperature, shell side operation pressure and operation temperature, container type, heat exchange tube specification and data, equipment importance level, service time, maintenance record and manufacturing unit of the heat exchange equipment are recorded in an equipment ledger; When the refining equipment is reactor equipment, the name, the process number, the model, the volume, the test pressure resistance value, the weight, the memory medium, the design temperature and the design pressure, the inlet temperature and the outlet temperature, the inlet pressure and the outlet pressure, the material, the thickness of the heat insulation material, the importance level of the equipment, the time of application, the maintenance record and the manufacturing unit of the reactor are recorded in the equipment ledger.
  5. 5. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 2, the two-dimensional codes are in one-to-one correspondence with the devices to be monitored, and the device account of the devices to be monitored can be called in real time by utilizing the intelligent mobile terminal to scan the two-dimensional codes, so that the basic information of the devices to be monitored can be obtained.
  6. 6. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 2, the two-dimensional code is attached to the surface of the device to be monitored in a mode of pasting, hanging and code spraying.
  7. 7. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 3, the measurement point of the device to be monitored is selected according to the pipeline inspection distribution point requirement in SY/T6553-2003, and then the initial measurement frequency of the device to be monitored is set according to the pipeline inspection frequency in SY/T6553-2003.
  8. 8. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein the thickness measuring ledger comprises a device name, a figure number, a position number of a measurement point, a diameter, a wall thickness, a material, an internal medium, a design temperature and a design pressure, an operation temperature and an operation pressure, a time for use, a time for measurement, a wall thickness for measurement and a time for next measurement of the device to be monitored.
  9. 9. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 4, a two-dimensional code on a device to be monitored is scanned by a code scanner of an intelligent mobile terminal to obtain position information of a measurement point, then the thickness of a wall body at the measurement point is measured by a thickness meter, and the measured thickness of the wall body is transmitted to a fixed-point thickness measurement corrosion monitoring processing center in real time, so that automatic correlation between the thickness measurement position and thickness measurement information is realized.
  10. 10. The method for monitoring corrosion based on fixed-point thickness measurement according to claim 1, wherein in step 5.2, the total thinning rate is calculated by a first calculation coefficient Set to 0.75, the second calculation coefficient of the total thinning rate Set to 0.25.
  11. 11. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 5.2, if the device to be monitored is a pipeline, the minimum bearing wall thickness of the device to be monitored is determined according to the specification of petrochemical pipeline design equipment in SY/T3059-2012, and if the device to be monitored is a refining device, the minimum bearing wall thickness of the device to be monitored is determined according to GB 150.3-2011.
  12. 12. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 5.2, when the device to be monitored is a pipe, the diameter of the pipe is not smaller than 100mm, and the thickness of the wall measured for the nth time is not more than 3mm, the remaining life of the pipe is directly determined to be 0 without calculation.
  13. 13. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, wherein in the step 6, if the monitoring level of the measurement point is a level, the wall thickness of the measurement point is measured every 3-6 months, if the monitoring level of the measurement point is B level, the wall thickness of the measurement point is measured every 6 months-2 years, and if the monitoring level of the measurement point is C level, the wall thickness of the measurement point is measured every 4 years or every operation cycle of the device to be monitored.

Description

Corrosion monitoring system and method based on fixed-point thickness measurement Technical Field The invention relates to the technical field of corrosion of oil refining chemical equipment, in particular to a corrosion monitoring system and method based on fixed-point thickness measurement. Background The corrosion of equipment and pipeline is taken as a prominent problem affecting the safe operation of the refining device, the operation stability of the refining device is seriously affected, the corrosion conditions of the equipment and the pipeline in the refining process flow are required to be monitored in real time, and effective protection and control measures are adopted before the equipment and the pipeline are seriously damaged due to corrosion. The ultrasonic fixed-point thickness measurement is used as the corrosion monitoring means with the widest application range at present, has the characteristics of simplicity in real time, lower cost, direct clear monitoring result and high reliability, and is commonly applied to corrosion monitoring of refining devices. At present, when corrosion prevention monitoring is carried out on equipment and pipelines of a modern large-scale refining device based on fixed-point thickness measurement, hundreds or even thousands of fixed-point thickness measurement monitoring points are required to be arranged, so that a large amount of data exists in corrosion prevention monitoring of the refining device based on fixed-point thickness measurement, and a plurality of defects still exist in operation and management of the current stage based on fixed-point thickness measurement monitoring, such as manual arrangement and input of monitoring data, low efficiency and easy error, manual reference of original account information in thickness measurement data processing is required, a result cannot be fed back in the first time after on-site measurement, expert experience is required to be relied on in preparation and adjustment of a thickness measurement data plan, scientific basis is lacked, and phenomena of missed detection and over detection are common. Relevant experts and scholars are researched by the intelligent thickness gauge, the problems of automatic uploading and recording of thickness measurement data are solved, the influence of artificial influence on the measurement of the thickness of equipment and the thickness of a pipeline is avoided, and the working efficiency of fixed-point thickness measurement is improved. The utility model patent CN 204228127U discloses a wireless intelligent thickness gauge, which comprises a host and a wireless ultrasonic probe, wherein an ultrasonic communication terminal is arranged on the host, the wireless ultrasonic probe is in wireless data communication with the ultrasonic communication terminal, the host processes the acquired thickness data, the host comprises a display screen, the display screen is a liquid crystal touch display screen, the acquired signals are directly transmitted to the host in a mode of matching the wireless ultrasonic probe with wireless transmission, wiring on the host and the probe is not needed, data is not needed to be recorded artificially, the working efficiency is improved, and meanwhile, the influence of human factors on the thickness measurement result is avoided. The utility model patent CN 206469863U discloses a multifunctional integrated inspection terminal device related to a pressure container and a pressure pipeline, which consists of an application software module, an automatic identification module and a thickness measuring module, wherein the automatic identification module and the thickness measuring module are organically combined through the application software module, so that the basic information of the device is quickly acquired, the accurate recording of thickness measuring data and positions is realized, the quality and the acquisition efficiency of the thickness measuring data are improved, the manual recording work of the thickness measuring data is not needed, and the information communication of the thickness measuring data is more timely and accurate. The invention patent CN103499438B discloses a material adaptability evaluation method based on residual life, which is characterized in that the predicted residual life is compared with the expected life, the residual life is smaller than the expected life of a user, even if an alarm is given, the corrosion rate is further analyzed, the corrosion rate exceeds a fortification value, and the material is recommended to be upgraded. The invention patent CN 112014303A discloses a corrosion early warning method and a device for equipment parts, which are characterized in that the corrosion rate is determined according to the original multi-type information data of the parts to be monitored, and the current residual wall thickness of the parts to be monitored is calculated according to the corrosion rate and the multi-type in