CN110906171B - Pipeline heat preservation condition monitoring and hierarchical control method based on dynamic envelope curve method - Google Patents
Pipeline heat preservation condition monitoring and hierarchical control method based on dynamic envelope curve method Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract
A pipeline heat preservation condition monitoring and grading control method based on a dynamic envelope curve method comprises the following steps: establishing an in-service pipeline heat preservation condition evaluation method, and judging whether the pipeline needs to be modified or not; monitoring the temperature of the in-service pipeline with the thermal insulation effect grade below grade C, and installing an optical fiber temperature measurement system consisting of a temperature controller and temperature measurement optical fibers on the outer wall of the thermal insulation layer of the monitored pipeline for monitoring; a wireless router with a 4G function is arranged on the outer wall of the insulating layer of the in-service pipeline, and is connected with a temperature controller through a 232 interface to realize real-time data transmission and data monitoring; an online monitoring system platform is set up in an upper PC; respectively drawing trend value point diagrams of heat dissipation loss of a pipeline heat preservation unit area and total heat dissipation loss of the pipeline, and drawing a pipeline heat preservation effect dynamic enveloping line diagram on the diagrams; and controlling the pipeline heat insulation effect according to the pipeline heat insulation effect dynamic envelope curve. The invention can diagnose the fault of the pipeline heat insulation material in early stage and take corresponding measures in time.
Description
Technical Field
The invention relates to a method for monitoring and controlling the heat preservation condition of a pipeline in a grading way. In particular to a pipeline heat preservation condition monitoring and grading control method based on a dynamic envelope curve method.
Background
A large number of process pipelines are arranged among production devices and inside the production devices of industrial enterprises, and the heat dissipation loss of the pipelines accounts for a large proportion of the energy consumption of the devices, for example, in a power steam pipe network system, steam is produced from a steam source and is conveyed to users through a pipe network, 5-20% of heat is lost, and the heat loss is higher particularly in rainy and snowy days, so that the normal production is influenced. The latest heat preservation investigation test result of a certain petrochemical enterprise pipeline shows that about 40 percent of the heat dissipation capacity of the process pipeline exceeds the standard. The process pipeline heat preservation relates to many aspects such as safety, energy saving, investment economy, because quantity kind, technical method, detection means, system standard etc. cause the process pipeline heat preservation management to have more problems at present, with the deepening of national energy saving and consumption reduction work, the technological level of improving process pipeline heat preservation management is urgently needed.
At the present stage, various domestic enterprises have extensive management on heat-insulating pipelines, and the pipeline reconstruction screening is mostly carried out by depending on experience, so that pipelines which are in urgent need of reconstruction are often laid, and limited reconstruction funds cannot be efficiently utilized; in the aspect of the transformation technology, a complete technical system and integrated design management are not formed from the heat preservation detection to the determination of the transformation scheme until the final transformation and the evaluation after the transformation, and as a result, due to improper selection of the heat preservation material and no standard design, the transformation cost is high and the heat dissipation loss of the heat preservation structure after the transformation is large; the operation monitoring is mainly realized by manual inspection, and the heat preservation problem is difficult to find in time. To date, there is no complete system and method for monitoring and managing the thermal insulation operation condition of the pipeline in a grading way.
Disclosure of Invention
The invention aims to solve the technical problem of providing a pipeline heat preservation condition monitoring and grading control method based on a dynamic envelope curve method, which can judge the operation state of pipeline heat preservation more intuitively and simply and carry out maintenance and early warning.
The technical scheme adopted by the invention is as follows: a pipeline heat preservation condition monitoring and grading control method based on a dynamic envelope curve method comprises the following steps:
1) establishing an in-service pipeline heat insulation condition evaluation method, evaluating the in-service pipeline heat insulation condition, and judging whether the pipeline needs to be modified or not according to an evaluation result;
2) the temperature monitoring is carried out on the in-service pipeline with the thermal insulation effect level below C level, the temperature measuring optical fiber starting point position is selected on the in-service pipeline with the thermal insulation effect level below C level, and an optical fiber temperature measuring system consisting of a temperature controller and temperature measuring optical fibers is arranged on the outer wall of the thermal insulation layer of the monitored pipeline for monitoring;
3) a wireless router with a 4G function is arranged on the outer wall of the heat-insulating layer of the in-service pipeline and is connected with a temperature controller through a 232 interface, and a temperature signal acquired by the temperature controller is transmitted to an upper PC (personal computer) through the wireless router to realize real-time data transmission and data monitoring;
4) an online monitoring system platform is set up in an upper PC, and comprises an established real-time database, data analysis and performance calculation, data query and display, and a real-time dynamic oscillogram for displaying the heat loss per unit area of the heat preservation of the pipeline, the position of the damaged part of the heat preservation layer and the heat loss of the whole pipeline through a display;
5) respectively drawing trend value point diagrams of the heat dissipation loss of the pipeline heat preservation unit area and the total heat dissipation loss of the pipeline, and drawing a dynamic envelope diagram of the pipeline heat preservation effect by adopting a moving average-standard difference method on the basis of the trend value point diagrams;
6) and controlling the pipeline heat insulation effect according to the pipeline heat insulation effect dynamic envelope curve.
According to the pipeline thermal insulation condition monitoring and grading control method based on the dynamic envelope curve method, the thermal insulation condition of an in-service pipeline is evaluated by compiling an in-service pipeline thermal insulation condition evaluation program, whether the pipeline needs to be modified or not is judged according to the evaluation result, and the pipeline thermal insulation condition monitoring and grading control method is incorporated into a pipeline thermal insulation running state monitoring and grading control system; the pipeline heat-preservation operation condition is monitored through the built wireless monitoring system network for the pipeline heat-preservation operation condition, and the occurrence of faults can be diagnosed in the early stage of the faults of the pipeline heat-preservation material by combining the energy-saving early warning control based on the dynamic envelope line, so that the working personnel are reminded to take corresponding measures in time. The method has the following advantages:
1. the method improves the modification fund utilization rate of the pipeline heat insulation modification project and the pipeline heat insulation management level, reduces the pipeline heat dissipation loss, reduces the production cost and guides the upgrading of the enterprise process pipeline heat insulation technology.
2. The wireless monitoring system network for the heat preservation operation condition of the built pipeline does not need to be stopped for installing temperature measuring equipment, does not influence the operation of the device, is flexible in configuration and stable in data transmission, can expand the physical range of heat preservation management of the pipeline at any time, and is stable in use and high in working efficiency.
3. By adopting a moving average-standard deviation method, a pipeline heat-preservation effect operation envelope curve diagram is dynamically drawn, the heat-preservation operation state of the pipeline can be judged more intuitively and simply, the heat-preservation operation condition of the pipeline is monitored, and the early diagnosis of the heat-preservation failure of the pipeline can be carried out by combining the maintenance early-warning management based on the dynamic envelope curve, so that the working personnel is reminded to take corresponding measures in time, the energy-saving and efficient operation of a production device is guided, and the safe operation and maintenance cost is reduced.
Drawings
FIG. 1 is a flow chart of a pipeline thermal insulation condition monitoring and grading control method based on a dynamic envelope curve method;
FIG. 2 is a schematic diagram of a wireless monitoring system for the heat preservation running state of an in-service pipeline;
FIG. 3 is an installation schematic diagram of an in-service pipeline heat-preservation integrated optical fiber temperature measurement system;
fig. 4 is a graph showing a trend value of a change in heat dissipation loss per unit area of a single-segment pipe.
Fig. 5 is a dynamic envelope diagram of the pipe insulation effect.
Detailed Description
The method for monitoring the thermal insulation condition of the pipeline and controlling the pipeline in a grading way based on the dynamic envelope curve method is described in detail by combining the embodiment and the attached drawings.
The invention discloses a pipeline heat preservation condition monitoring and grading control method based on a dynamic envelope curve method, which is a method for applying a pipeline heat preservation effect grading and running state real-time monitoring system shown in figures 1 and 2. The monitoring result of the running condition of the pipeline heat preservation is mainly influenced by two factors, namely a system factor and a random factor, in the running process of the pipeline heat preservation, the stability and the normality of the running state are mainly concerned, if the system factor or the random factor with larger variability exists in the running process, the average value and the standard deviation of the measurement result can be abnormally fluctuated, and the running state of the pipeline heat preservation can be considered to be unstable. And if the overall distribution parameters (average value and standard deviation) of the data of the heat dissipation loss test result of the heat preservation of the pipeline are basically kept unchanged or are within an allowable range, the operation process of the heat preservation of the pipeline is considered to be stable. If the distribution parameters exceed the allowable range, the reason of deviation should be analyzed, and measures are taken in time to adjust the operation state of the pipeline heat preservation.
The flow chart of the pipeline thermal insulation condition monitoring and hierarchical control method based on the dynamic envelope curve method given in fig. 1 is a control method for carrying out hierarchical evaluation on the pipeline thermal insulation effect by calling the pipeline thermal insulation structural parameters and performance parameters in the pipeline thermal insulation real-time database and the pipeline thermal insulation heat dissipation loss detection values.
As shown in fig. 1, the method for monitoring and controlling the thermal insulation condition of the pipeline based on the dynamic envelope curve method comprises the following steps:
1) establishing an in-service pipeline heat insulation condition evaluation method, evaluating the in-service pipeline heat insulation condition, and judging whether the pipeline needs to be modified or not according to an evaluation result; the method for evaluating the heat preservation condition of the in-service pipeline determines whether the in-service pipeline needs to be modified or not by calculating a key index, and specifically comprises the following steps:
(1) through different pipeline insulation material characteristics of contrastive analysis to carry out statistical analysis to pipeline heat preservation infrared thermal imaging testing result, pipeline heat preservation damage point's historical information, determine six influence factors of the key index of pipeline heat preservation effect, do respectively: the heat dissipation of the pipeline per unit area, the performance of a pipeline heat-insulating material, the temperature of an operating medium in the pipeline, the thickness of a pipeline heat-insulating layer, the operating life of the pipeline heat-insulating layer and the number of damaged points of the whole pipeline heat-insulating layer;
(2) the method comprises the following steps of determining the weight of six influence factors of a key index of the pipeline heat insulation effect by applying an analytic hierarchy process, wherein the weight is as follows:
the heat dissipation loss grade weight b1 of the unit area of the pipeline is 0.35;
the performance grade weight b2 of the pipeline heat insulation material is 0.17;
the weight b3 of the temperature grade of the operating medium in the pipeline is 0.13;
the weight b4 of the thickness grade of the insulating layer of the pipeline is 0.16;
the grade weight b5 of the operating age limit of the pipeline heat-insulating layer is 0.1;
the quantity grade weight b6 of the damaged points of the whole pipeline heat-insulating layer is 0.09;
(3) grading standard for determining key factors of pipeline heat insulation effect
(3.1) the scoring criterion of the heat dissipation rate per unit area of the pipeline is to calculate the heat dissipation rate per unit area q of the heat insulation layer of the pipeline1Difference q from maximum allowable heat loss q of pipeline specified in industrial equipment and pipeline insulation engineering design specificationseTo determine qe＝q1-q,qeThe larger the value, the lower the rating, the scoring criteria are:
qeless than 5, 5 minutes;
qegreater than 5 and less than or equal to 20, and is 4 minutes;
qegreater than 20 and less than or equal to 50, which is 3 minutes;
qegreater than 50 and less than or equal to 100, which is 2 minutes;
qegreater than 100, 1 point;
(3.2) performance grading standard of the pipeline thermal insulation material:
the pipeline heat-insulating material is a novel nano aerogel product, and the content is 5 min;
the pipeline heat insulation material is an aluminum silicate product, and the number of the products is 4;
the pipeline heat insulation material is a microporous calcium silicate product, and the number of the microporous calcium silicate product is 3 min;
the pipeline heat insulation material is rock wool products and is divided into 2 parts;
the pipeline heat-insulating material is other materials except a novel nano aerogel product, an aluminum silicate product, a microporous calcium silicate product and a rock wool product, and is divided into 1 minute;
(3.3) operating medium temperature scoring standard in the pipeline:
the temperature of the operating medium in the pipeline is less than 100 ℃ and is 5 minutes;
the temperature of the operation medium in the pipeline is more than or equal to 100 ℃ and less than 200 ℃ and is 4 minutes;
the temperature of the operation medium in the pipeline is more than or equal to 200 ℃ and less than 300 ℃ and is 3 minutes;
the temperature of the medium in the pipeline is more than or equal to 300 ℃ and less than 450 ℃, and is 2 minutes;
the temperature of the medium in the pipeline is more than or equal to 450 ℃ and is 1 minute;
(3.4) grading standard of the thickness of the heat-insulating layer of the pipeline by calculating the economic thickness D of the heat-insulating layer of the pipeline1With actual thickness D of the insulating layer2Difference D ofeTo determine the economic thickness D of the pipe insulating layer1Is obtained by calculation according to a calculation formula in the design specification of industrial equipment and pipeline heat insulation engineering, DeThe larger the value, the lower the rating, the scoring criteria were:
Dethe value is greater than 0mm and less than or equal to 5, and is 5 minutes;
Dethe value is greater than 5mm and less than or equal to 10mm, and is 4 minutes;
Dethe value is greater than 10mm and less than or equal to 20mm, and is 3 minutes;
Dethe value is greater than 20mm and less than or equal to 30mm, and is 2 minutes;
Dethe value is greater than 30mm and is 1 minute;
(3.5) the operating life scoring standard of the pipeline heat-insulating layer is as follows:
the service life of the pipeline heat-insulating layer is less than or equal to 3 years and is 5 minutes;
the service life of the pipeline heat-insulating layer is more than 3 years and less than or equal to 5 years, and is 4 minutes;
the service life of the pipeline heat-insulating layer is more than 5 years and less than or equal to 8 years, and is 3 minutes;
the service life of the pipeline heat-insulating layer is more than 8 years and less than or equal to 15 years, and is 2 minutes;
the service life of the pipeline heat-insulating layer is more than 15 years and is 1 minute;
(3.6) whole piece pipeline heat preservation damaged point number standard of grading, the heat preservation appears damaged promptly, through detecting damaged position temperature and surpassing 50 ℃ position to and the valve of pipeline, pipeline support piece, pipeline dysmorphism piece appear the position that the temperature surpassed 50 ℃, damaged point number value is big more, and the grade is lower more, and the standard of grading is:
the use process of the pipeline heat-insulating layer is up to now, no damage point exists, and the number is 5;
the number of damaged points is less than or equal to 10 and is 4 minutes in the using process of the pipeline heat-insulating layer;
the number of the damaged points is more than 10 and less than or equal to 30, and is 3 minutes;
the number of the damaged points is more than 30 and less than or equal to 50, and is 2 minutes;
the number of damaged points is more than 50 and is 1 minute in the use process of the pipeline heat-insulating layer;
(4) calculating key indexes of pipeline thermal insulation performance and judging whether modification is needed
The comprehensive calculation formula of the key degree index K of the heat insulation performance of the pipeline is as follows:
K＝b1x score of heat dissipation per unit area of pipe + b2X score of pipe insulation Performance + b3X score of operating Medium temperature in pipe + b4Score of x pipe insulation thickness + b5Score value + b of x pipeline insulation operating years6Scoring the number of damaged points of the insulation layer of the whole pipeline;
scoring all factors of in-service pipeline heat preservation in an enterprise according to the scoring criterion, substituting the scores of all factors into a comprehensive calculation formula of a pipeline heat preservation performance criticality index K to obtain a critical index K of the heat preservation condition of each pipeline, and evaluating whether the pipeline needs to be modified according to the following criterion;
when the key index K is 4.0-5, the pipeline has excellent heat insulation effect, the grade of the heat insulation effect is A grade, and the heat insulation design, construction and operation maintenance scheme of the pipeline is used as the design target value of the pipeline with the same outer diameter and the same internal medium temperature;
when the key index K is 2.8-4.0, the heat preservation effect of the pipeline is good, the grade of the heat preservation effect is B grade, the heat preservation of the pipeline needs to be checked every two years, and the heat dissipation loss condition of the heat preservation of the pipeline is analyzed and calculated;
when the key index K is 1.9-2.8, the pipeline has a common heat insulation effect, the grade of the heat insulation effect is grade C, and the improvement is recommended; if not, performing sampling inspection on the pipeline heat insulation every year, and analyzing and calculating the heat dissipation loss condition of the pipeline heat insulation;
when the key index K is 1.0-1.9, the pipeline heat preservation effect is poor, the heat preservation effect level is D level, the transformation is urgently needed, and the design and construction of the transformation refer to the pipeline with the A level heat preservation effect for design and construction.
2) The temperature monitoring is carried out on the in-service pipeline with the thermal insulation effect level below C level, the initial point position of a temperature measuring optical fiber is selected on the in-service pipeline with the thermal insulation effect level below C level, and an optical fiber temperature measuring system consisting of a DTSX200 temperature controller produced by a river crossing motor and the temperature measuring optical fiber is arranged on the outer wall of the thermal insulation layer of the monitored pipeline for monitoring;
fig. 2 shows a system architecture of a pipeline thermal insulation monitoring system, which includes a temperature controller 1 for processing optical signals, a measured pipeline 2 for installing temperature measuring optical fibers, a wireless router 10 with 4G function, an RS232 controller 9 for connecting the temperature controller and the wireless router, a cloud server 11 for receiving data uploaded by the temperature controller, and an upper PC 12.
In fig. 3, a mounting structure of a temperature measuring optical fiber is shown, which includes a temperature controller 1, a temperature measuring optical fiber 3, a temperature measuring optical fiber 4 and a temperature measuring optical fiber 5, wherein the temperature measuring optical fiber 3, the temperature measuring optical fiber 4 and the temperature measuring optical fiber 5 are respectively laid along the circumferential direction of the surface of the thermal insulation layer at the end of the pipeline to be monitored, the temperature measuring optical fiber is adhered to the outermost layer for heat preservation 7, and the outer surface of the temperature measuring optical fiber is wrapped by an aluminum skin 8.
The specific installation is as shown in fig. 3, and comprises:
(1) selecting 3 points of 0 degree, 60 degrees and 300 degrees along the circumferential direction of the surface of the heat-insulating layer at the tail end of the pipeline to be monitored as the installation starting points of the temperature-measuring optical fibers respectively;
(2) installing temperature measuring optical fibers on the surface of the insulating layer of the pipeline to be monitored along the pipeline direction, specifically, laying 3 temperature measuring optical fibers in parallel from selected 3 points of 0 degree, 60 degrees and 300 degrees to the head end of the pipeline to be monitored, fixing the temperature measuring optical fibers by using a steel belt, and tightly adhering to the outermost layer of the insulating surface, wherein the maximum bending radius of the temperature measuring optical fibers is 38 mm;
(3) the head end of the pipeline to be monitored is provided with a temperature controller which is connected with the temperature measuring optical fiber and is used for generating laser injected into the temperature measuring optical fiber and receiving a group of optical fiber temperatures transmitted by the temperature measuring optical fiber and temperature point position signals of the optical fiber temperatures in the group, and the temperature controller defines the interval set length of the temperature measuring optical fiber as a temperature measuring signal acquisition point.
3) As shown in fig. 2, a wireless router with a 4G function is arranged on the outer wall of the insulating layer of the in-service pipeline, and is connected with a temperature controller through a 232 interface, and a temperature signal acquired by the temperature controller is transmitted to an upper PC through the wireless router, so that real-time data transmission and data monitoring are realized;
4) an online monitoring system platform is set up in an upper PC, and comprises an established real-time database, data analysis and performance calculation, data query and display, and a real-time dynamic oscillogram for displaying the heat loss per unit area of the heat preservation of the pipeline, the position of the damaged part of the heat preservation layer and the heat loss of the whole pipeline through a display; the method comprises the following steps:
(1) building a real-time database
Establishing a real-time database for storing structural parameters and performance parameters of pipeline heat insulation, the maximum allowable heat dissipation loss value of the pipeline heat insulation at each temperature of a medium in a pipe, the ambient temperature and the wind speed of a pipeline accessory, pipeline heat insulation temperature data and corresponding position data which are transmitted to an upper host system by an optical fiber temperature measurement system, and temperature, pressure and flow data of the medium in the pipe, which are extracted from a DCS;
(2) establishing a spatial position model of the monitored pipeline, establishing a pipeline heat-preservation position coordinate data structure by taking a temperature measurement point as a sampling point according to the laying position of the temperature measurement optical fiber, and storing position data into a real-time database;
(3) calculating the heat-insulating performance of the on-line pipeline, namely calculating the heat-dissipating loss of the pipeline in unit heat-insulating area and calculating the total heat-dissipating loss of the pipeline, wherein,
(3.1) calculation of Heat dissipation loss per unit area of pipeline Heat preservation
The heat loss of the pipeline heat preservation unit area is calculated according to the surface temperature, the environment temperature and the surface heat exchange coefficient of the pipeline and according to the following formula:
q＝α×(TW-TF) (1)
in the formula: q is the heat flux density in W/m 2; alpha is surface heat exchange coefficient and has the unit of W/(m 2K); t isWThe temperature of the outer surface of the pipeline heat-insulating layer is represented by K; t isFIs ambient temperature in K;
wherein: the surface heat transfer coefficient α is obtained by the following formula:
in the formula: omega is the wind speed, with the unit of m/s,
temperature T of outer surface of pipeline heat-insulating layerWProcessing according to an arithmetic mean value method:
in the formula:
T(xi1,yi1,zi1),T(xi2,yi2,zi2),T(xi3,yi3,zi3) Three optical fibers are laid on the outer surface of the heat insulation layer of the pipeline along the direction of the pipeline, a sampling section vertical to the direction of the pipeline is taken at each temperature measurement signal acquisition point, the sampling sections are n sections in total, and the temperature values of the optical fiber temperature measurement points of the ith sampling section are respectively recorded as T (x)i1,yi1,zi1)、T(xi2,yi2,zi2)、T(xi3,yi3,zi3) In units of;
(3.2) calculation of Total Heat loss of the pipeline
The total heat dissipation loss of the pipeline is calculated according to the following formula:
in the formula:
q is the total heat dissipation loss of the pipeline, and the unit is W; qiThe heat dissipation loss of the ith section of pipeline is W; q. q.siThe unit area heat dissipation loss of the ith section of pipeline is W/m 2; d1iThe outer radius of the ith section of pipeline is m; d2iThe thickness of the heat insulation layer of the ith section of pipeline is m; liIs the length of the ith segment of pipeline and has the unit of m.
5) Respectively drawing trend value point diagrams of the heat dissipation loss of the pipeline heat preservation unit area and the total heat dissipation loss of the pipeline, and drawing a dynamic envelope diagram of the pipeline heat preservation effect by adopting a moving average-standard deviation method on the basis of the trend value point diagrams, as shown in FIG. 5; the method comprises the following steps:
(1) calculating the average value of the total heat dissipation loss Q
And standard deviation σQk
Selecting data of zero point time of tenth day of stable operation of the monitored pipeline as sampling initial point data, and collecting temperature data, environment temperature data and current data of the heat-insulating outer wall of each section of pipeline by taking every 30 minutes as a sampling periodWind speed data, medium temperature data in the pipe and position data of each section of pipeline are calculated, and the heat dissipation rate q per unit area of each section of pipeline i in each sampling period j is calculatedijAnd total heat loss Q of the pipejCalculating the average value of the total heat dissipation loss of the current sampling period of the pipeline, and recording the average value as
Total standard deviation sigma of heat dissipation loss of whole pipeline in current sampling periodQkObtained by the following formula:
in the formula:
qij-the heat dissipation per unit area of the pipeline heat preservation of the jth sampling period of the ith segment of pipeline;
Qj-total heat loss per sampling period of the whole pipeline;
σQkthe standard deviation of the total heat dissipation loss calculation value of k sampling periods is obtained currently by the whole pipeline;
k is the number of sampling periods;
(2) determination of the upper envelope value for normal operation
For the total heat dissipation loss of pipeline heat insulation, the upper envelope value Q of the normal operationuelObtained by the following formula:
(3) determination of abnormal envelope values for abnormal operation
Abnormal envelope value Q of abnormal operation of whole pipeline heat preservation effectyelObtained by the following formula:
enveloping value Q for heat preservation and overhaul of whole pipelinerelObtained by the following formula:
(4) limit value of heat dissipation per unit area of each section of pipeline
Determining the maximum allowable heat dissipation rate per unit area under the temperature of the medium in the pipe according to the design specifications of industrial equipment and pipeline heat insulation engineering, and taking the maximum allowable heat dissipation rate as the limit value q of the heat dissipation rate per unit area of each section of pipeline heat insulationLELNamely, each section of pipeline heat preservation maintenance early warning line;
(5) measuring data in each sampling period under the normal operation condition of the pipeline, including the temperature data of the heat-insulating outer wall of each section of pipeline, the ambient temperature data, the current wind speed data, the external surface area of each section of pipeline and the temperature data of the medium in the pipeline, and calculating the heat loss q per unit area of the heat-insulating heat dissipation of each section of pipeline in each sampling periodijCalculating the total heat dissipation loss Q of the pipeline in each sampling periodj(ii) a The number of sampling periods is used as an abscissa, and the heat dissipation rate q per unit area of each section of pipeline heat preservation in each sampling periodijThe sampling period is a coordinate, the heat dissipation loss value of each section of pipeline heat preservation unit area in each sampling period is respectively positioned on the coordinate point of the sampling period, and the limit value q of the heat dissipation loss of the pipeline heat preservation unit area corresponding to the current sampling period of the section of pipeline is setLELPoints are arranged on the coordinate point of the sampling period and are used as a heat preservation maintenance early warning line qKIRSo as to obtain a trend value point diagram (as shown in fig. 4) reflecting the change of the heat dissipation loss of the unit area of the single-section pipeline; taking the number of sampling periods as the abscissa, tubesThe total heat dissipation loss Q of the pipeline heat preservation is a vertical coordinate, and the upper envelope value Q of the normal operation of the total heat dissipation loss of the pipeline in each sampling perioduelAbnormal envelope value Q of abnormal operationyelAnd the heat preservation overhaul envelope value QrelRespectively points on the coordinate point of the current sampling period to determine the upper envelope line Q of the normal operation of the pipelineUELAbnormal envelope Q of abnormal operationYELAnd heat preservation maintenance envelope line QRELDrawing a dynamic envelope curve diagram of the heat preservation effect of the pipeline, and dividing the diagram into an area A, an area B, an area C and an area D, wherein the area A is an upper envelope curve Q in normal operationUELThe lower area is a normal operation area; zone B is the upper envelope Q of normal operationUELAbnormal envelope Q associated with abnormal operationYELThe area between the two is a key attention area; zone C is the anomalous envelope Q for anomalous operationYELFrom the above to the thermal insulation maintenance envelope QRELThe area D is a heat preservation maintenance envelope line QRELThe above area is a whole pipeline maintenance area; in a trend value point diagram of the unit area heat dissipation loss change of the single-section pipeline, a heat preservation maintenance early warning line q of the unit area heat dissipation loss of the pipeline heat preservationKIRThe area below is a single-section pipeline maintenance early warning area; and taking the dynamic envelope curve of the pipeline heat insulation effect as a basis for analyzing the daily actual operation trend of the pipeline heat insulation effect and determining the heat insulation maintenance time.
6) And controlling the pipeline heat insulation effect according to the pipeline heat insulation effect dynamic envelope curve.
The method comprises the steps of monitoring operation data of pipeline heat preservation in real time, and calculating the heat dissipation rate q per unit area of each pipeline i in each sampling period j according to the monitoring dataijAnd total heat dissipation loss Q per sampling period jjThe two calculated values are compared with a trend value point diagram of the change of the heat loss of the unit area of the single-section pipeline of the pipeline and a pipeline heat preservation effect dynamic envelope diagram respectively, so that heat preservation effect analysis and heat preservation maintenance early warning can be carried out, and the specific analysis standard is as follows:
(1) total heat dissipation loss Q per sampling period jjThe heat dissipation per unit area q of each section of pipeline i is positioned in the area A and each sampling period jijIn the maintenance precaution line q of heat preservationKIRThe heat preservation operation condition of the section of pipeline is normal as described above;
(2) total heat dissipation loss Q per sampling period jjThe heat dissipation per unit area q of each section of pipeline i in the area B and each sampling period jijIn the maintenance precaution line q of heat preservationKIRThe heat preservation operation condition of the section of pipeline is normal as described above;
(3) total heat dissipation loss Q per sampling period jjThe heat dissipation per unit area q of each section of pipeline i in the C area and each sampling period jijIn the maintenance precaution line q of heat preservationKIRIn the above, the process parameters are adjusted on the premise of meeting the process requirements;
(4) total heat dissipation loss Q per sampling period jjHeat dissipation per unit area q per pipe section i in zone D, or more than one quarter of each sampling period jijIn the maintenance precaution line q of heat preservationKIRPerforming overall maintenance early warning of the heat preservation of the pipeline; if the heat dissipation loss per unit area of each section of pipeline exceeds the limit value q of the heat dissipation loss per unit area of heat preservation of each section of pipelineLELAnd maintaining the section for heat preservation if the temperature is more than 30%.
Claims (4)
1. A pipeline heat preservation condition monitoring and grading control method based on a dynamic envelope curve method is characterized by comprising the following steps:
1) establishing an in-service pipeline heat insulation condition evaluation method, evaluating the in-service pipeline heat insulation condition, and judging whether the pipeline needs to be modified or not according to an evaluation result; the method for evaluating the heat preservation condition of the in-service pipeline determines whether the in-service pipeline needs to be modified or not by calculating a key index, and specifically comprises the following steps:
(1) through different pipeline insulation material characteristics of contrastive analysis to carry out statistical analysis to pipeline heat preservation infrared thermal imaging testing result, pipeline heat preservation damage point's historical information, determine six influence factors of the key index of pipeline heat preservation effect, do respectively: the heat dissipation of the pipeline per unit area, the performance of a pipeline heat-insulating material, the temperature of an operating medium in the pipeline, the thickness of a pipeline heat-insulating layer, the operating life of the pipeline heat-insulating layer and the number of damaged points of the whole pipeline heat-insulating layer;
(2) the method comprises the following steps of determining the weight of six influence factors of a key index of the pipeline heat insulation effect by applying an analytic hierarchy process, wherein the weight is as follows:
the heat dissipation loss grade weight b1 of the unit area of the pipeline is 0.35;
the performance grade weight b2 of the pipeline heat insulation material is 0.17;
the weight b3 of the temperature grade of the operating medium in the pipeline is 0.13;
the weight b4 of the thickness grade of the insulating layer of the pipeline is 0.16;
the grade weight b5 of the operating age limit of the pipeline heat-insulating layer is 0.1;
the quantity grade weight b6 of the damaged points of the whole pipeline heat-insulating layer is 0.09;
(3) grading standard for determining key factors of pipeline heat insulation effect
(3.1) the scoring criterion of the heat dissipation rate per unit area of the pipeline is to calculate the heat dissipation rate per unit area q of the heat insulation layer of the pipeline1Difference q from maximum allowable heat loss q of pipeline specified in industrial equipment and pipeline insulation engineering design specificationseTo determine qe＝q1-q,qeThe larger the value, the lower the rating, the scoring criteria are:
qeless than 5, 5 minutes;
qegreater than 5 and less than or equal to 20, and is 4 minutes;
qegreater than 20 and less than or equal to 50, which is 3 minutes;
qegreater than 50 and less than or equal to 100, which is 2 minutes;
qegreater than 100, 1 point;
(3.2) performance grading standard of the pipeline thermal insulation material:
the pipeline heat-insulating material is a novel nano aerogel product, and the content is 5 min;
the pipeline heat insulation material is an aluminum silicate product, and the number of the products is 4;
the pipeline heat insulation material is a microporous calcium silicate product, and the number of the microporous calcium silicate product is 3 min;
the pipeline heat insulation material is rock wool products and is divided into 2 parts;
the pipeline heat-insulating material is other materials except a novel nano aerogel product, an aluminum silicate product, a microporous calcium silicate product and a rock wool product, and is divided into 1 minute;
(3.3) operating medium temperature scoring standard in the pipeline:
the temperature of the operating medium in the pipeline is less than 100 ℃ and is 5 minutes;
the temperature of the operation medium in the pipeline is more than or equal to 100 ℃ and less than 200 ℃ and is 4 minutes;
the temperature of the operation medium in the pipeline is more than or equal to 200 ℃ and less than 300 ℃ and is 3 minutes;
the temperature of the medium in the pipeline is more than or equal to 300 ℃ and less than 450 ℃, and is 2 minutes;
the temperature of the medium in the pipeline is more than or equal to 450 ℃ and is 1 minute;
(3.4) grading standard of the thickness of the heat-insulating layer of the pipeline by calculating the economic thickness D of the heat-insulating layer of the pipeline1With actual thickness D of the insulating layer2Difference D ofeTo determine the economic thickness D of the pipe insulating layer1Is obtained by calculation according to a calculation formula in the design specification of industrial equipment and pipeline heat insulation engineering, DeThe larger the value, the lower the rating, the scoring criteria were:
Dethe value is greater than 0mm and less than or equal to 5, and is 5 minutes;
Dethe value is greater than 5mm and less than or equal to 10mm, and is 4 minutes;
Dethe value is greater than 10mm and less than or equal to 20mm, and is 3 minutes;
Dethe value is greater than 20mm and less than or equal to 30mm, and is 2 minutes;
Dethe value is greater than 30mm and is 1 minute;
(3.5) the operating life scoring standard of the pipeline heat-insulating layer is as follows:
the service life of the pipeline heat-insulating layer is less than or equal to 3 years and is 5 minutes;
the service life of the pipeline heat-insulating layer is more than 3 years and less than or equal to 5 years, and is 4 minutes;
the service life of the pipeline heat-insulating layer is more than 5 years and less than or equal to 8 years, and is 3 minutes;
the service life of the pipeline heat-insulating layer is more than 8 years and less than or equal to 15 years, and is 2 minutes;
the service life of the pipeline heat-insulating layer is more than 15 years and is 1 minute;
(3.6) whole piece pipeline heat preservation damaged point number standard of grading, the heat preservation appears damaged promptly, through detecting damaged position temperature and surpassing 50 ℃ position to and the valve of pipeline, pipeline support piece, pipeline dysmorphism piece appear the position that the temperature surpassed 50 ℃, damaged point number value is big more, and the grade is lower more, and the standard of grading is:
the use process of the pipeline heat-insulating layer is up to now, no damage point exists, and the number is 5;
the number of damaged points is less than or equal to 10 and is 4 minutes in the using process of the pipeline heat-insulating layer;
the number of the damaged points is more than 10 and less than or equal to 30, and is 3 minutes;
the number of the damaged points is more than 30 and less than or equal to 50, and is 2 minutes;
the number of damaged points is more than 50 and is 1 minute in the use process of the pipeline heat-insulating layer;
(4) calculating key indexes of pipeline thermal insulation performance and judging whether modification is needed
The key index K of the pipeline thermal insulation performance is comprehensively calculated according to the following formula:
K＝b1x score of heat dissipation per unit area of pipe + b2X score of pipe insulation Performance + b3X score of operating Medium temperature in pipe + b4Score of x pipe insulation thickness + b5Score value + b of x pipeline insulation operating years6Scoring the number of damaged points of the insulation layer of the whole pipeline;
scoring the factors of the heat insulation performance of the in-service pipeline in an enterprise according to the scoring criterion, substituting the scores of the factors into a comprehensive calculation formula of key indexes K of the heat insulation performance of the pipeline to obtain the key indexes K of the heat insulation condition of each pipeline, and evaluating whether the pipeline needs to be modified according to the following criterion;
when the key index K is 4.0-5, the pipeline has excellent heat insulation effect, the grade of the heat insulation effect is A grade, and the heat insulation design, construction and operation maintenance scheme of the pipeline is used as the design target value of the pipeline with the same outer diameter and the same internal medium temperature;
when the key index K is 2.8-4.0, the heat preservation effect of the pipeline is good, the grade of the heat preservation effect is B grade, the heat preservation of the pipeline needs to be checked every two years, and the heat dissipation loss condition of the heat preservation of the pipeline is analyzed and calculated;
when the key index K is 1.9-2.8, the pipeline has a common heat insulation effect, the grade of the heat insulation effect is grade C, and the improvement is recommended; if not, performing sampling inspection on the pipeline heat insulation every year, and analyzing and calculating the heat dissipation loss condition of the pipeline heat insulation;
when the key index K is 1.0-1.9, the pipeline has poor heat insulation effect, the heat insulation effect level is D level, the modification is urgently needed, and the modified design and construction refer to the pipeline with A level heat insulation effect for design and construction;
2) monitoring the temperature of the in-service pipeline with the heat preservation effect grade below grade C: selecting a temperature measuring optical fiber starting point position on an in-service pipeline with the thermal insulation effect grade below grade C, and installing an optical fiber temperature measuring system consisting of a temperature controller and temperature measuring optical fibers on the outer wall of a thermal insulation layer of the monitored pipeline for monitoring;
3) a wireless router with a 4G function is arranged on the outer wall of the heat-insulating layer of the in-service pipeline and is connected with a temperature controller through a 232 interface, and a temperature signal acquired by the temperature controller is transmitted to an upper PC (personal computer) through the wireless router to realize real-time data transmission and data monitoring;
4) an online monitoring system platform is set up in an upper PC, and comprises an established real-time database, data analysis and performance calculation, data query and display, and a real-time dynamic oscillogram for displaying the heat loss per unit area of the heat preservation of the pipeline, the position of the damaged part of the heat preservation layer and the heat loss of the whole pipeline through a display; the method comprises the following steps:
(1) building a real-time database
Establishing a real-time database for storing structural parameters and performance parameters of pipeline heat preservation, the maximum allowable heat dissipation loss value of the pipeline heat preservation at each temperature of a medium in a pipe, the ambient temperature and the wind speed of a pipeline accessory, pipeline heat preservation temperature data and corresponding position data which are transmitted to an upper host system by an optical fiber temperature measurement system, and temperature, pressure and flow data of the medium in the pipe, which are extracted from a DCS;
(2) establishing a spatial position model of the monitored pipeline, establishing a pipeline heat-preservation position coordinate data structure by taking a temperature measurement point as a sampling point according to the laying position of the temperature measurement optical fiber, and storing position data into a real-time database;
(3) calculating the heat-insulating performance of the on-line pipeline, namely calculating the heat-dissipating loss of the pipeline in unit heat-insulating area and calculating the total heat-dissipating loss of the pipeline, wherein,
(3.1) calculation of Heat dissipation loss per unit area of pipeline Heat preservation
The heat loss of the pipeline heat preservation unit area is calculated according to the surface temperature, the environment temperature and the surface heat exchange coefficient of the pipeline and according to the following formula:
q＝α×(TW-TF) (1)
in the formula: q is the heat flux density in W/m 2; alpha is surface heat exchange coefficient and has the unit of W/(m 2K); t isWThe temperature of the outer surface of the pipeline heat-insulating layer is represented by K; t isFIs ambient temperature in K;
wherein: the surface heat transfer coefficient α is obtained by the following formula:
in the formula: omega is the wind speed, with the unit of m/s,
temperature T of outer surface of pipeline heat-insulating layerWProcessing according to an arithmetic mean value method:
in the formula:
T(xi1,yi1,zi1),T(xi2,yi2,zi2),T(xi3,yi3,zi3) Three optical fibers are laid on the outer surface of the heat insulation layer of the pipeline along the direction of the pipeline, a sampling section vertical to the direction of the pipeline is taken at each temperature measurement signal acquisition point, the sampling sections are n sections in total, and the temperature values of the optical fiber temperature measurement points of the ith sampling section are respectively recorded as T (x)i1,yi1,zi1)、T(xi2,yi2,zi2)、T(xi3,yi3,zi3) In units of;
(3.2) calculation of Total Heat loss of the pipeline
The total heat dissipation loss of the pipeline is calculated according to the following formula:
in the formula:
q is total heat dissipation loss of the pipeline, and the unit is W; qiThe heat dissipation loss of the ith section of pipeline is W; q. q.siThe unit area heat dissipation loss of the ith section of pipeline is W/m 2; d1iThe outer radius of the ith section of pipeline is m; d2iThe thickness of the heat insulation layer of the ith section of pipeline is m; liThe length of the ith section of pipeline is m;
5) respectively drawing trend value point diagrams of the heat dissipation loss of the pipeline heat preservation unit area and the total heat dissipation loss of the pipeline, and drawing a dynamic envelope diagram of the pipeline heat preservation effect by adopting a moving average-standard difference method on the basis of the trend value point diagrams;
6) and controlling the pipeline heat insulation effect according to the pipeline heat insulation effect dynamic envelope curve.
2. The pipeline thermal insulation condition monitoring and grading control method based on the dynamic envelope curve method as claimed in claim 1, wherein the step 2) comprises:
(1) selecting 3 points of 0 degree, 60 degrees and 300 degrees along the circumferential direction of the surface of the heat-insulating layer at the tail end of the pipeline to be monitored as the installation starting points of the temperature-measuring optical fibers respectively;
(2) installing temperature measuring optical fibers on the surface of the insulating layer of the pipeline to be monitored along the pipeline direction, specifically, laying 3 temperature measuring optical fibers in parallel from selected 3 points of 0 degree, 60 degrees and 300 degrees to the head end of the pipeline to be monitored, fixing the temperature measuring optical fibers by using a steel belt, and tightly adhering to the outermost layer of the insulating surface, wherein the maximum bending radius of the temperature measuring optical fibers is 38 mm;
(3) the head end of the pipeline to be monitored is provided with a temperature controller which is connected with the temperature measuring optical fiber and is used for generating laser injected into the temperature measuring optical fiber and receiving a group of optical fiber temperatures transmitted by the temperature measuring optical fiber and temperature point position signals of the optical fiber temperatures in the group, and the temperature controller defines the interval set length of the temperature measuring optical fiber as a temperature measuring signal acquisition point.
3. The pipeline thermal insulation condition monitoring and grading control method based on the dynamic envelope curve method as claimed in claim 1, wherein the step 5) comprises:
(1) calculating the average value of the total heat dissipation loss Q of the pipeline
And standard deviation σQk
Selecting data of zero point time of the tenth day of stable operation of the monitored pipeline as sampling initial point data, collecting temperature data of the heat-insulating outer wall of each section of pipeline, environment temperature data, current wind speed data, medium temperature data in the pipeline and position data of each section of pipeline by taking every 30 minutes as a sampling period, and calculating the heat loss q per unit area of each section of pipeline i of each sampling period jijAnd total heat loss Q of the pipejCalculating the average value of the total heat dissipation loss of the current sampling period of the pipeline, and recording the average value as
Total standard deviation sigma of heat dissipation loss of whole pipeline in current sampling periodQkObtained by the following formula:
in the formula:
qij-the heat dissipation per unit area of the pipeline heat preservation of the jth sampling period of the ith segment of pipeline;
Qj-total heat loss per sampling period of the whole pipeline;
σQkthe standard deviation of the total heat dissipation loss calculation value of k sampling periods is obtained currently by the whole pipeline;
k is the number of sampling periods;
(2) determination of the upper envelope value for normal operation
For the total heat dissipation loss of pipeline heat insulation, the upper envelope value Q of the normal operationuelObtained by the following formula:
(3) determination of abnormal envelope values for abnormal operation
Abnormal envelope value Q of abnormal operation of whole pipeline heat preservation effectyelObtained by the following formula:
enveloping value Q for heat preservation and overhaul of whole pipelinerelObtained by the following formula:
(4) limit value of heat dissipation per unit area of each section of pipeline
Determining the maximum allowable heat dissipation rate per unit area under the temperature of the medium in the pipe according to the design specifications of industrial equipment and pipeline heat insulation engineering, and taking the maximum allowable heat dissipation rate as the limit value q of the heat dissipation rate per unit area of each section of pipeline heat insulationLELNamely, each section of pipeline heat preservation maintenance early warning line;
(5) measuring data in each sampling period under the normal operation condition of the pipeline, including the temperature data of the heat-insulating outer wall of each section of pipeline, the ambient temperature data, the current wind speed data, the external surface area of each section of pipeline and the temperature data of the medium in the pipeline, and calculating the heat loss q per unit area of the heat-insulating heat dissipation of each section of pipeline in each sampling periodijCalculating the total heat dissipation loss Q of the pipeline in each sampling periodj(ii) a The number of sampling periods is used as an abscissa, and the heat dissipation rate q per unit area of each section of pipeline heat preservation in each sampling periodijThe sampling period is a coordinate, the heat dissipation loss value of each section of pipeline heat preservation unit area in each sampling period is respectively positioned on the coordinate point of the sampling period, and the limit value q of the heat dissipation loss of the pipeline heat preservation unit area corresponding to the current sampling period of the section of pipeline is setLELPoints are arranged on the coordinate point of the sampling period and are used as a heat preservation maintenance early warning line qKIRSo as to obtain a trend value point diagram reflecting the change of the heat dissipation loss of the unit area of the single-section pipeline; taking the number of sampling periods as an abscissa, the total heat dissipation loss Q of the pipeline as an ordinate, and the upper envelope value Q of the normal operation of the total heat dissipation loss of the pipeline in each sampling perioduelAbnormal envelope value Q of abnormal operationyelAnd the heat preservation overhaul envelope value QrelRespectively points on the coordinate point of the current sampling period to determine the upper envelope line Q of the normal operation of the pipelineUELAbnormal operation of abnormal packageWinding line QYELAnd heat preservation maintenance envelope line QRELDrawing a dynamic envelope curve diagram of the heat preservation effect of the pipeline, and dividing the diagram into an area A, an area B, an area C and an area D, wherein the area A is an upper envelope curve Q in normal operationUELThe lower area is a normal operation area; zone B is the upper envelope Q of normal operationUELAbnormal envelope Q associated with abnormal operationYELThe area between the two is a key attention area; zone C is the anomalous envelope Q for anomalous operationYELFrom the above to the thermal insulation maintenance envelope QRELThe area D is a heat preservation maintenance envelope line QRELThe above area is a whole pipeline maintenance area; in a trend value point diagram of the unit area heat dissipation loss change of the single-section pipeline, a heat preservation maintenance early warning line q of the unit area heat dissipation loss of the pipeline heat preservationKIRThe area below is a single-section pipeline maintenance early warning area; and taking the dynamic envelope curve of the pipeline heat insulation effect as a basis for analyzing the daily actual operation trend of the pipeline heat insulation effect and determining the heat insulation maintenance time.
4. The method for monitoring and controlling the thermal insulation condition of the pipeline based on the dynamic envelope curve method as claimed in claim 1, wherein the step 6) is implemented by monitoring the operation data of the pipeline thermal insulation in real time and calculating the heat loss q per unit area of each pipeline i in each sampling period j according to the monitoring dataijAnd total heat dissipation loss Q per sampling period jjThe two calculated values are compared with a trend value point diagram of the unit area heat dissipation loss change of the single-section pipeline and a pipeline heat preservation effect dynamic envelope diagram respectively, so that heat preservation effect analysis and heat preservation maintenance early warning can be carried out, and the specific analysis standard is as follows:
(1) total heat dissipation loss Q per sampling period jjThe heat dissipation per unit area q of each section of pipeline i is positioned in the area A and each sampling period jijIn the maintenance precaution line q of heat preservationKIRThe heat preservation operation condition of the section of pipeline is normal as described above;
(2) total heat dissipation loss Q per sampling period jjThe heat dissipation per unit area q of each section of pipeline i in the area B and each sampling period jijKeep warmRepair early warning line qKIRThe heat preservation operation condition of the section of pipeline is normal as described above;
(3) total heat dissipation loss Q per sampling period jjThe heat dissipation per unit area q of each section of pipeline i in the C area and each sampling period jijIn the maintenance precaution line q of heat preservationKIRIn the above, the process parameters are adjusted on the premise of meeting the process requirements;
(4) total heat dissipation loss Q per sampling period jjHeat dissipation per unit area q per pipe section i in zone D, or more than one quarter of each sampling period jijIn the maintenance precaution line q of heat preservationKIRPerforming overall maintenance early warning of the heat preservation of the pipeline; if the heat dissipation loss per unit area of each section of pipeline exceeds the limit value q of the heat dissipation loss per unit area of heat preservation of each section of pipelineLELAnd maintaining the section for heat preservation if the temperature is more than 30%.
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