CN-121994916-A - Metal pipeline and equipment corrosion defect online monitoring system and method based on pulse vortex

CN121994916ACN 121994916 ACN121994916 ACN 121994916ACN-121994916-A

Abstract

The invention belongs to the technical field of corrosion detection of oil gas storage and transportation and petrochemical equipment, and discloses a pulse vortex-based metal pipeline and equipment corrosion defect online monitoring system and method. The system comprises a hardware and a software system, wherein the hardware comprises a pulse vortex surface detection sensor unit and an on-line monitor, a motor running track, a stepping motor and a multi-sensor synchronous motion module are integrated in the sensor unit, a 'stop-go-pick-go' time-sharing working mode is adopted, and the software comprises a data processing and analyzing and corrosion early warning and system display module. The invention supports real-time/non-real-time differential monitoring, can realize automatic monitoring from point measurement to surface coverage according to a corrosion rate matching monitoring strategy, intuitively displays corrosion distribution and evolution trend through multilayer penetration imaging, differential analysis and three-dimensional morphology reconstruction, realizes high-precision and high-reliability operation by adopting explosion-proof packaging, and solves the problems of small monitoring range, high cost and incapability of automatic surface monitoring in the prior art.

Inventors

TAO JIANTAO
LIU QINGLONG
Yin le
ZHAO XUEWEI
BAI JIE
HUA YUCHEN
LI XINGZHOU

Assignees

天津因科新创科技有限公司

Dates

Publication Date: 20260508
Application Date: 20260410

Claims (11)

1. The on-line monitoring system for corrosion defects of metal pipelines and equipment based on pulse vortex is characterized by comprising a hardware system and a software system; The hardware system comprises a pulse vortex surface detection sensor unit and a pulse vortex on-line monitor; the pulse vortex surface detection sensor unit is of an integrated structure and is packaged by an explosion-proof shell, a motor running track, a high-precision stepping motor and a multi-sensor synchronous motion module are integrated in the pulse vortex surface detection sensor unit, at least two pulse excitation probes and signal receiving probes which are distributed in an array are integrated in the multi-sensor synchronous motion module, and the pulse vortex surface detection sensor unit is used for field data acquisition; The pulse vortex on-line monitor comprises a pulse signal transmitting and signal collecting unit, a motor operation control unit, a remote data transmission unit and a power supply, and is used for providing signal transmitting, collecting, power supply and control functions for the pulse vortex surface detection sensor unit and packaging and transmitting collected data, and the pulse vortex on-line monitor is in communication connection with the pulse vortex surface detection sensor unit in a wired mode; the software system comprises a data processing and analyzing module and a system display module; The data processing and analyzing module is used for carrying out usability judgment, multidimensional feature extraction, multilayer penetration imaging, differential analysis, three-dimensional morphology display, corrosion rate, residual life calculation and early warning level confirmation on the received data, and automatically uploading a data analysis result and an image to the system display module; The system display module is used for visually displaying corrosion related conditions including but not limited to analysis images, corrosion states and residual life of pipe fitting data, and simultaneously automatically analyzing and giving maintenance and protection measures suggestions according to early warning levels and historical monitoring results of equipment.
2. The pulse vortex-based metal pipeline and equipment corrosion defect online monitoring system according to claim 1 is characterized in that the type of the pulse vortex surface detection sensor unit comprises, but is not limited to, a planar type, an arc type or a circumferential cladding type so as to be respectively matched with detection parts of a storage tank, equipment, a pipeline or a connecting pipe, and the specification and the appearance of a motor running track are adjusted according to the detection parts so that the multi-sensor synchronous movement module is switched to a matched working mode.
3. The pulse vortex based metal pipe and equipment corrosion defect online monitoring system of claim 1, wherein the types of pulse vortex surface detection sensor units comprise, but are not limited to, conventional surface detection sensor units, high-precision surface detection sensor units or high lift-off detection sensor units to respectively aim at corrosion defects comprising, but not limited to, wall thickness reduction, body weld cracks and under-insulation pipe corrosion, and the multi-sensor synchronous motion module is adapted to different types of special pulse vortex surface detection sensors.
4. The pulse vortex based metal pipeline and equipment corrosion defect online monitoring system is characterized in that the pulse vortex online monitor comprises a real-time pulse vortex online monitor and a non-real-time pulse vortex online monitor, the pulse vortex surface detection sensor units are operated in a time-sharing working mode under the driving of the real-time pulse vortex online monitor and the non-real-time pulse vortex online monitor, the real-time pulse vortex online monitor is fixedly installed on site and is connected with a matched pulse vortex surface detection sensor unit group to automatically and continuously monitor a detected pipe fitting with severe corrosion development and high speed, the non-real-time pulse vortex online monitor does not need to be fixedly installed, a person holds the pipe fitting position of the installed pulse vortex surface detection sensor unit, and the pulse vortex surface detection sensor unit is driven to automatically complete data acquisition according to a preset time-sharing working mode after connection, so that round monitoring is achieved.
5. The pulse vortex-based metal pipeline and equipment corrosion defect online monitoring system according to claim 1 is characterized in that the motor operation control unit controls the high-precision stepper motor to operate in a time-sharing working mode, wherein the time-sharing working mode is specifically that the high-precision stepper motor drives the multi-sensor synchronous motion module to move for a preset number of steps and then stops, pulse vortex signals are emitted and data are acquired in a motor stop state, and the high-precision stepper motor is started to move again after acquisition is completed, so that a cycle work flow of 'walking-stopping-collecting-walking' is formed.
6. The pulse eddy current-based metal pipeline and equipment corrosion defect online monitoring system according to claim 1, wherein in the multi-sensor synchronous motion module, the number and the distance between the pulse excitation probe and the signal receiving probe are adjustable so as to adapt to different detection precision requirements.
7. The pulsed eddy current based metal pipe and equipment corrosion defect online monitoring system of claim 1, wherein the data processing and analysis module comprises: The system comprises a data availability judging unit, an abnormality detection model and a data processing unit, wherein the data availability judging unit is used for carrying out availability judgment on an acquired voltage attenuation curve, automatically identifying and removing abnormal data; The multi-dimensional feature extraction unit is used for extracting features of different dimensions according to different defect types, extracting feature values reflecting wall thickness change from effective signals according to wall thickness thinning defects, and converting the feature values into wall thickness values by combining a material exclusive calibration curve; The defect multilayer penetration imaging unit is used for reconstructing characteristic data into corrosion distribution images of different depth layers and superposing the corrosion distribution images to form a three-dimensional corrosion distribution map, wherein the images are multilayer penetration imaging images, and the abscissa corresponds to the position of the pulse vortex surface detection probe, and the ordinate or the color maps the characteristic value; The image differential analysis unit is used for constructing a differential matrix by taking initial acquired data as a reference through differential operation of each measuring point and each time window and generating a corrosion change trend graph, and specifically comprises the steps of defining a response value of a jth time window of an ith measuring point in the reference data as V ij , and a response value of a corresponding measuring point and a time window in the current acquired data as C ij , wherein the differential value S ij =V ij -C ij has physical meaning of electromagnetic response variation of a monitored object relative to an initial state at the position of the corresponding measuring point and the time window, and the variation is directly related to the evolution degree of a defect; The three-dimensional defect morphology display unit is used for stacking images of all layers according to depth proportion to reconstruct three-dimensional morphology of defects, and concretely comprises the steps of obtaining an original corrosion area A k of each layer based on calculation of a defect multi-layer penetrating imaging unit, wherein k represents a layer number, k takes values of 1,2 from the deepest layer, q is the total number of physical depth, carrying out inverse mapping and scaling reduction on the original corrosion area A k of each layer based on a signal diffusion model calibrated in advance in a laboratory, eliminating signal diffusion effect caused by an imaging technology to obtain a real equivalent corrosion area A k' after correction of each layer, sequentially carrying out the following treatment on the k layer and the k-1 layer of two adjacent layers from the deepest layer k=1, obtaining a wall thickness value h k corresponding to the k layer, carrying out linear interpolation filling between the adjacent layers to enable corrosion area parameters to be continuously changed in the thickness direction, thus constructing the three-dimensional morphology of the defects, carrying out integral interpolation operation on the wall thickness h k corresponding to each layer based on a continuous function after that, reconstructing the volume V k of an adjacent layer, completing the linear interpolation operation on the wall thickness h k corresponding to the adjacent layer and the total volume of each layer, and carrying out total volume interpolation operation to obtain a total volume k , and the total volume defect volume display formula, and carrying out total volume summation and the three-dimensional defect calculation: Wherein Δh k is the corresponding thickness increment of the kth layer; the corrosion rate calculation unit is used for carrying out linear fitting on all wall thickness graphs based on the wall thickness data of the historical time sequence to calculate the corrosion rate; the residual service life calculating unit is used for calculating the residual service life according to the current minimum wall thickness, the allowable minimum wall thickness and the corrosion rate; The grading early warning unit is used for calculating a comprehensive risk score according to weighted comprehensive evaluation of the thinning rate, the corrosion allowance and the corrosion rate, and dividing the alarm grade according to a score threshold, wherein the thinning rate is calculated according to the original wall thickness and the current minimum wall thickness, and the corrosion allowance is calculated according to the current minimum wall thickness and the allowable minimum wall thickness.
8. The pulse eddy current based metal pipe and equipment corrosion defect online monitoring system of claim 1, wherein the system comprises dedicated monitoring calibration curves preset for different materials of carbon steel, stainless steel and alloy steel respectively.
9. The pulse eddy current based metal pipe and equipment corrosion defect online monitoring system of claim 1, wherein the remote data transmission unit comprises, but is not limited to, a bluetooth module, a 4G module, a 5G module, an internet of things communication module and a local storage module, wherein the local storage module is used for temporarily storing collected data when a network is interrupted and automatically transmitting the data after the network is restored.
10. The pulsed eddy current based metal pipe and equipment corrosion defect online monitoring system of claim 1, wherein the corrosion defects include, but are not limited to, wall thickness thinning defects, body cracking defects, and weld cracking defects of metal pipes and equipment.
11. The pulse vortex-based metal pipeline and equipment corrosion defect online monitoring method is applied to the pulse vortex-based metal pipeline and equipment corrosion defect online monitoring system according to any one of claims 1 to 10, and is characterized by comprising the following steps: step S1, system deployment and parameter setting According to the geometric shape of the equipment to be detected and the monitoring range requirement, adjusting the running track of the motor to an adaptive monitoring mode, establishing communication connection between the pulse vortex on-line monitor and the pulse vortex surface detection sensor unit, and presetting acquisition time parameters, acquisition cycle parameters, stepping parameters and signal transmitting and receiving parameters through the pulse vortex on-line monitor; Step S2, automatic wake-up and time-sharing data acquisition For real-time monitoring, the system automatically wakes up according to preset time, and the pulse eddy current on-line monitor controls the high-precision stepping motor to drive the multi-sensor synchronous motion module to execute a cycle working mode of 'running-stopping-collecting-running' along a motor running track: ① The multi-sensor synchronous motion module stops after moving for a preset step number; ② The pulse excitation probe is controlled to emit an adaptive pulse eddy current signal, and the signal receiving probe is controlled to acquire a secondary magnetic field attenuation signal; ③ Associating the acquired data of the current point position with the point position information and the acquisition time, and then temporarily storing; ④ Repeating the steps until the collection of all preset points is completed; For non-real-time monitoring, a person holds the pulse vortex on-line monitor and moves the pulse vortex on-line monitor to the positions of the pipe fittings provided with the pulse vortex surface detection sensor units respectively, after the monitor is connected with the sensor units, equipment automatically drives the sensor units to execute a cycle of 'running-stopping-collecting-running' according to preset stepping parameters and a time-sharing working mode, and data collection of single or multiple pipe fittings is sequentially completed; step S3, data encapsulation and remote transmission The equipment automatically encrypts and encapsulates the acquired data and the equipment state information, and sends the encrypted and encapsulated data and the equipment state information to a data server for storage through a remote data transmission unit; step S4, data processing and multidimensional analysis Processing and analyzing the acquired data, including: ① Carrying out usability judgment on the acquired data, and eliminating invalid data with abnormal voltage attenuation characteristics; ② Extracting a characteristic value reflecting wall thickness change from the effective data; ③ Carrying out multilayer penetration imaging processing according to the characteristic values to generate corrosion distribution images of different depth layers, and superposing the corrosion distribution images to form a three-dimensional corrosion distribution map; ④ Performing differential analysis on the corrosion image at the current moment and the reference image at the historical moment, constructing a difference matrix by taking initial acquired data as a reference, and generating a corrosion change trend multilayer penetration imaging image; ⑤ Performing linear fitting based on the wall thickness data of the historical time sequence, and calculating the corrosion rate; ⑥ Calculating the remaining service life of the equipment according to the current minimum wall thickness, the allowable minimum wall thickness and the corrosion rate; ⑦ Based on weighted comprehensive evaluation of the thinning rate, the corrosion allowance and the corrosion rate, calculating a comprehensive risk score, and dividing the early warning level according to a score threshold; Step S5, visual display of results And (3) visually displaying the multilayer penetration imaging graph, the corrosion change trend graph, the three-dimensional corrosion distribution graph, the corrosion rate, the residual service life and the early warning grade information generated in the step (S4) through a system display module, and automatically analyzing and giving out maintenance and protection measures suggestions based on the historical monitoring results.

Description

Metal pipeline and equipment corrosion defect online monitoring system and method based on pulse vortex Technical Field The invention relates to the technical field of corrosion detection of oil gas storage and transportation and petrochemical equipment, in particular to a pulse vortex-based metal pipeline and equipment corrosion defect online monitoring system and method. Background The petrochemical industry is used as a support industry of national economy, and the production flow of the petrochemical industry is highly dependent on various metal static devices such as metal pipelines, storage tanks, reaction kettles and the like. The equipment is extremely easy to generate various defects such as uniform corrosion, pitting corrosion, stress corrosion and the like under the severe working conditions of high temperature, high pressure, inflammability and explosiveness for a long time. Because the corrosion defect has the characteristics of strong concealment, slow development process and strong randomness of evolution rules, if the corrosion defect is not monitored in time and effective prevention and control measures are taken, the leakage of a pipeline and equipment failure are directly caused, and serious safety accidents such as fire and explosion are further caused, so that serious environmental pollution and huge economic loss are caused. Therefore, the on-line corrosion monitoring of metal pipelines and equipment is developed, and the on-line corrosion monitoring becomes a core guarantee link for the safety production of petrochemical enterprises. However, the current corrosion monitoring technology of static equipment in petrochemical industry still has obvious short plates. Unlike the real-time on-line monitoring of parameters such as temperature, noise, vibration and the like of dynamic equipment such as pumps, compressors and the like, the static equipment is restricted by factors such as large monitoring coverage area, low corrosion change speed, strong randomness of defect generation and development and the like, and the existing corrosion monitoring technology is difficult to realize differential and low-cost automatic full-coverage on-line monitoring. At present, the static equipment corrosion monitoring of petrochemical enterprises mainly adopts the following technologies: The first category is ultrasonic point measurement techniques. The technology can realize the accurate detection of single-point wall thickness, and is a real-time monitoring means widely applied at present. However, the technology has obvious application limitations that firstly, single-point data acquisition can be completed, the coverage area is small, the corrosion distribution condition of the whole equipment cannot be reflected, local corrosion defects are easy to miss, secondly, for large-scale static equipment, detection is completed by manually moving the measuring points for many times, the detection efficiency is low, automatic continuous monitoring cannot be realized, and the core requirement of large-area monitoring of the static equipment is difficult to adapt. The second category is invasive monitoring techniques such as corrosion tabs, resistive probes, etc. The technology needs to directly implant the sensor into the equipment, and can acquire accurate corrosion data, but the technology can damage the integrity of the equipment, influence normal production and has higher later maintenance cost. The third category is non-invasive monitoring techniques such as ultrasonic guided wave, radiation detection, etc. Although the technology does not interfere with the production flow, the technology has the inherent defects of low detection efficiency, difficulty in realizing real-time online monitoring, easiness in site environment interference and the like. The pulsed eddy current detection technology is used as a novel non-invasive electromagnetic detection technology, has the unique advantages of no need of couplant, deep detection depth, non-contact measurement and the like, and has good application prospect in the wall thickness reduction detection of pressure-bearing equipment. However, the current mainstream pulsed eddy current testing equipment still takes offline and manual operation as the main principle, and most of application modes are spot inspection or local scanning, so that various monitoring strategies such as real-time continuous monitoring and non-real-time tour monitoring cannot be flexibly matched according to corrosion rate differences of different parts of the equipment, thus urgent requirements of petrochemical engineering static equipment on continuous, real-time and key area full-coverage corrosion monitoring are difficult to meet, and equipment deployment and operation and maintenance costs are high when wide area monitoring is realized. In summary, there is a lack of a corrosion monitoring system and method that can match a monitoring mode according to a difference in corrosion rates,