CN110967382A - Metal corrosion and coating integrity monitoring system under heat preservation layer - Google Patents
Metal corrosion and coating integrity monitoring system under heat preservation layer Download PDFInfo
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Abstract
The invention discloses a system for monitoring metal corrosion and coating integrity under a heat-insulating layer, which comprises a corrosion sensor, a coating impedance monitoring sensor and a monitor, wherein the corrosion sensor and the coating impedance monitoring sensor are arranged in the heat-insulating layer at intervals, the corrosion sensor and the coating impedance monitoring sensor are electrically connected with the input end of the monitor, the corrosion sensor is used for collecting corrosion current information and sending the corrosion current information to the monitor, and the monitor is used for analyzing the corrosion current information and obtaining the corrosion rate of a pipeline according to an analysis result; the coating impedance monitoring sensor is used for collecting electrochemical signals, the monitor is used for analyzing the electrochemical signals, and an electrochemical alternating current impedance value is obtained according to the analysis result. The invention is designed to monitor the corrosion rate of the pipeline under the heat-insulating layer, the coating impedance, the temperature and the humidity in real time by combining the corrosion monitoring technology and the coating impedance monitoring technology, and evaluate the corrosion tendency of the metal matrix under the heat-insulating layer and the aging state of the coating in multiple dimensions.
Description
Technical Field
The invention relates to the field of corrosion monitoring systems, in particular to a system for monitoring metal corrosion and coating integrity under a heat-insulating layer.
Background
Corrosion Under Insulation (CUI) refers to a corrosion phenomenon on the outer surface of a pipe or equipment that is wrapped with insulation. Localized corrosion of the outer surface of the pipe or equipment is typically caused by the ingress of condensate into the insulation system. When moisture exists in the heat preservation, electrochemical corrosion and crevice corrosion are easy to occur, and the corrosion is difficult to detect due to the covering of the surface layer. Along with the continuous accumulation of moisture in the heat insulation layer, the heat insulation effect is reduced, the coating on the metal surface is aged and bubbled, and the corrosion of the metal matrix is aggravated. Under extreme conditions, the pipeline corrodes the perforation and reveals, causes the incident.
At present, in the prior art, the corrosion under the heat-insulating layer is researched from the aspects of a corrosion experiment device, a mathematical analysis method, a corrosion test piece and the like, and the corrosion of a pipeline under the heat-insulating layer and the damage monitoring of a coating cannot be carried out in real time. This patent carries out the state aassessment under the heat preservation from a plurality of dimensions such as corrosion monitoring, coating integrality monitoring, humiture monitoring, can realize long period, real-time supervision.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a system for monitoring metal corrosion and coating integrity under a heat-insulating layer, which is used for evaluating the corrosion tendency of a metal matrix under the heat-insulating layer and the aging state of a coating, and the technical scheme is as follows:
the invention provides a metal corrosion and coating integrity monitoring system under a heat-insulating layer, wherein a coating and the heat-insulating layer are sequentially arranged outside a pipeline from bottom to top, the monitoring system comprises a corrosion sensor, a coating impedance monitoring sensor and a monitor, the corrosion sensor and the coating impedance monitoring sensor are both arranged in the heat-insulating layer and are arranged at intervals, the corrosion sensor and the coating impedance monitoring sensor are both electrically connected with the input end of the monitor, the corrosion sensor is used for collecting corrosion current information and sending the corrosion current information to the monitor, and the monitor is used for analyzing the corrosion current information and obtaining the corrosion rate of the pipeline according to the analysis result; the coating impedance monitoring sensor is used for collecting electrochemical signals, and the monitor is used for analyzing the electrochemical signals and obtaining an electrochemical alternating-current impedance value according to the analysis result.
Further, the corrosion sensor comprises a first protective cover and a second protective cover which are oppositely arranged, and a galvanic probe arranged in the first protective cover and the second protective cover, wherein the galvanic probe comprises a metal electrode, a graphite electrode and an insulating film arranged between the metal electrode and the graphite electrode which are oppositely arranged.
Furthermore, a circuit board which is arranged opposite to the galvanic couple probe is arranged in the first protective cover and the second protective cover, a temperature sensor and a humidity sensor are integrated on the circuit board, and a distance is kept between the circuit board and the galvanic couple probe.
Furthermore, all have a plurality of trompils on the side of first protection casing, be provided with on the corrosion sensor and be used for connecting the first connecting wire of monitor.
Furthermore, a positioning piece for fixing the circuit board and the galvanic probe is further arranged in the first protective cover and the second protective cover, and at least two positioning grooves are formed in the positioning piece.
Further, coating impedance monitoring sensor includes the backup pad and sets up the boss in the backup pad, be provided with two at least trompils on the boss, be provided with the insulated wire in the trompil, the outside surface of boss and backup pad all is sprayed and is equipped with the coating, the boss is provided with outward and is used for connecting the second connecting wire of monitor.
Further, the monitor includes transmitting unit, measuring unit, data processing unit, data memory cell, data transmission unit, display screen and data conversion unit, transmitting unit is used for to monitoring sensor transmission sine wave potential signal, monitoring sensor is used for feeding back to sine wave potential signal and obtains electrochemical signal and send to measuring unit, measuring unit is used for measuring electrochemical signal in order to obtain response signal, data processing unit is used for calculating electrochemical signal and response signal and obtains impedance signal, data conversion unit is used for converting impedance signal into the data format that the display screen can show.
Furthermore, the monitor also comprises a power module, a control mechanism and an alarm connected with the control mechanism, wherein when the detected impedance value is lower than a target threshold value, the control mechanism triggers the alarm to work.
Further, the range of the target threshold is set to 106Ω-1012Ω。
Further, the coating impedance monitoring sensors are arranged in three, and the three are distributed at equal intervals along the circumferential direction of the pipeline.
The technical scheme provided by the invention has the following beneficial effects:
a. the monitoring system for metal corrosion and coating integrity under the heat-insulating layer combines a corrosion monitoring technology and a coating impedance monitoring technology, monitors the corrosion rate of a pipeline under the heat-insulating layer, the coating impedance, the temperature and the humidity in real time through system integration, and evaluates the corrosion tendency of a metal matrix under the heat-insulating layer and the aging state of a coating in multiple dimensions;
b. the multifunctional corrosion sensor and the coating impedance sensor are applied for the first time by an electrochemical monitoring means.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a schematic view of the installation of a system for monitoring metal corrosion and coating integrity under an insulating layer according to an embodiment of the present invention;
FIG. 2 is a cross-sectional view of a corrosion sensor of a system for monitoring metal corrosion and coating integrity under insulation according to an embodiment of the present invention;
FIG. 3 is an exploded view of a galvanic couple probe of a system for monitoring metal corrosion and coating integrity under insulation according to an embodiment of the present invention;
FIG. 4 is a perspective view of a coating impedance monitoring sensor of a system for monitoring metal corrosion and coating integrity under insulation according to an embodiment of the present invention;
FIG. 5 is a graph of temperature versus time for a system for monitoring metal corrosion and coating integrity under insulation according to an embodiment of the present invention;
FIG. 6 is a graph of the impedance of a system for monitoring metal corrosion and coating integrity under an insulation layer according to an embodiment of the present invention over time;
FIG. 7 is a graph of corrosion current over time for a system for monitoring metal corrosion and coating integrity under an insulation layer according to an embodiment of the present invention;
FIG. 8 is a graph of corrosion current density over time for a system for monitoring metal corrosion and coating integrity under insulation provided by an embodiment of the present invention.
Wherein the reference numerals include: 1-pipeline, 2-insulating layer, 3-corrosion sensor, 31-first protective cover, 32-second protective cover, 33-galvanic probe, 34-positioning piece, 331-metal electrode, 332-graphite electrode, 333-insulating film, 4-coating impedance monitoring sensor, 41-supporting plate, 42-boss, 43-opening hole, 5-monitor, 6-circuit board and 7-second connecting wire.
Detailed Description
In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and claims of the present invention and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in sequences other than those illustrated or described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, apparatus, article, or device that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or device.
In an embodiment of the invention, a metal corrosion and coating integrity monitoring system under a heat-insulating layer is provided, and the specific structure is shown in fig. 1, wherein a coating and a heat-insulating layer are sequentially arranged outside a pipeline from bottom to top, the monitoring system comprises a corrosion sensor 3, a coating impedance monitoring sensor 4 and a monitor 5, the corrosion sensor 3 and the coating impedance monitoring sensor 4 are both arranged in the heat-insulating layer and are arranged at intervals, the corrosion sensor 3 and the coating impedance monitoring sensor 4 are both electrically connected with an input end of the monitor 5, the corrosion sensor 3 is used for collecting corrosion current information and sending the corrosion current information to the monitor, and the monitor is used for analyzing the corrosion current information and obtaining the corrosion rate of the pipeline according to an analysis result; the coating impedance monitoring sensor 4 is used for collecting electrochemical signals, and the monitor is used for analyzing the electrochemical signals and obtaining an electrochemical alternating-current impedance value according to the analysis result.
The specific structure of the corrosion sensor 3 is as follows: referring to fig. 2 and 3, the corrosion sensor 3 includes a first protective cover 31 and a second protective cover 32 which are oppositely arranged, and a galvanic probe 33 which is arranged in the first protective cover 31 and the second protective cover 32, the galvanic probe 33 includes a metal electrode 331, a graphite electrode 332 which are oppositely arranged, and an insulating film 333 which is arranged between the metal electrode 331 and the graphite electrode 332, and the material of the metal electrode 331 is the same as that of the pipeline. The first protective cover 31 and the second protective cover 32 are also internally provided with a circuit board 6 which is arranged opposite to the galvanic couple probe 33, a distance is kept between the circuit board 6 and the galvanic couple probe 33, the circuit board 6 is integrated with a temperature sensor and a humidity sensor, and the coating impedance monitoring sensor, the temperature sensor and the humidity sensor respectively perform different functions and cannot be in contact with each other; the first protection cover 31 has a plurality of openings 43 on the side surface thereof, which facilitates ventilation and simulation of real environment. The first protective cover 31 and the second protective cover 32 are further provided with a positioning piece 34 for fixing the circuit board 6 and the galvanic probe 33, the positioning piece 34 is provided with at least two positioning grooves, and the circuit board 6 and the galvanic probe 33 are located in the corresponding positioning grooves to prevent the movement of the two. And a first connecting wire for connecting the monitor 5 is arranged on the corrosion sensor 3.
The working principle of the corrosion sensor 3 is as follows: based on the principle of a galvanic probe 33, corrosion current and corrosion current density are measured by monitoring the number of electron loss of the metal to be detected, so that the corrosion rate of the pipeline is reflected, the corrosion rate of the pipeline is monitored, and meanwhile, a temperature sensor and a humidity sensor are integrated to measure the change conditions of the environmental temperature and the humidity in the heat-insulating layer.
The specific structure of the coating impedance monitoring sensor 4 is as follows: referring to fig. 4, the coating impedance monitoring sensor 4 includes a support plate 41 and a boss 42 disposed on the support plate 41, the boss 42 is provided with at least two openings 43, an insulating wire is disposed in the openings 43, then the outer side surfaces of the boss 42 and the support plate 41 are both coated with a coating, and the insulating wire cannot be separated from the openings 43 after the insulating wire is coated; the material of the coating is the same as that of the outer coating of the pipeline; and a second connecting wire 7 for connecting the monitor 5 is arranged outside the boss 42, and the monitor is used for monitoring the impedance value between the insulated wire and the boss coating.
The coating impedance sensors are embedded in the heat insulation layer of the outer wall of the pipeline, preferably three coating impedance monitoring sensors 4 are arranged, and the three coating impedance monitoring sensors are distributed at equal intervals along the circumferential direction of the pipeline, namely, the three coating impedance monitoring sensors are arranged at 120 degrees along the radial plane of the pipeline, so that the monitoring data are more accurate; the multifunctional corrosion sensor 3 is arranged separately from the coating resistance sensor, and the distance between the multifunctional corrosion sensor and the coating resistance sensor is controlled to be 1-2 m.
The coating impedance monitoring sensor 4 is based on the Electrochemical Impedance Spectroscopy (EIS) principle, and the sensor is shown in fig. 4. The coating impedance monitoring is based on electrochemical response when small-amplitude perturbation is applied to a system, the original data of each measured frequency point comprises phase shift of applied signal voltage (or current) to measured signal current (or voltage) and an impedance amplitude module value, an impedance spectrogram can be obtained, a real part and an imaginary part of the electrochemical response can be calculated according to the data, and variables such as impedance amplitude module (| Z |), phase shift (theta) and the like are obtained.
Specifically, the monitor includes transmitting unit, measuring unit, data processing unit, data memory cell, data transmission unit, display screen and data conversion unit, the transmitting unit is used for to monitoring sensor transmission sine wave potential signal, coating impedance monitoring sensor is used for feeding back sine wave potential signal and obtains electrochemical signal and send to measuring unit, measuring unit is used for measuring electrochemical signal in order to obtain response signal, data processing unit is used for calculating electrochemical signal and response signal and obtains impedance signal, data conversion unit is used for converting impedance signal into the data format that the display screen can show, can see the impedance value promptly on the display screen. The data storage unit is used for storing impedance data.
The relationship between the pipeline coating damage and the impedance value is as follows: 1) the coating is not damaged and has a resistance value of 106Ω-1012Omega; 2) the coating has cracks or small-area damage, the impedance value is obviously reduced, and the order of magnitude is reduced by 103Left and right; the resistance value is reduced along with the increase of the damaged area, so that whether the coating is damaged or not can be known through the change of the resistance valueAnd (4) loss.
The corrosion sensor 3 and the coating impedance monitoring sensor 4 are both arranged in the heat-insulating layer, and if the corrosion sensor directly contacts with the pipeline, the pipeline can be damaged.
The metal corrosion and coating integrity monitoring system under the heat-insulating layer is based on the corrosion electrochemical principle, adopts the alternating current impedance and galvanic couple current technology, transmits information such as corrosion current, temperature and humidity, impedance and the like to the processing unit through various sensors arranged under the heat-insulating layer, converts signals and stores the information into the main control unit, and data can be copied on site through Bluetooth and a data downloader. And monitoring the change of each parameter under the heat-insulating layer for a long time, and judging the states of the coating under the heat-insulating layer and the metal body.
In an embodiment provided by the invention, the system for monitoring metal corrosion and coating integrity under the heat-insulating layer provided by the invention is used for monitoring a certain nuclear power plant chilled water pipeline with coating aging and pipeline corrosion conditions under the heat-insulating layer, and the pipeline is made of A106GR.B (ASTM). The chilled water system provides 8 ℃ chilled water for the cooling coils of the air conditioning system of the main control room, the ventilation system of the electric appliance factory building and the ventilation system of the cable layer, and the temperature rise in the electric factory building after the chilled water system fails can finally cause the unit of the power plant to stop running.
The test procedure was as follows: embedding the corrosion sensor and the coating impedance sensor into the heat insulation layer along the pipe wall, wherein the corrosion sensor 3 and the coating impedance sensor are separately arranged, and the distance between the corrosion sensor and the coating impedance sensor is controlled to be 1-2 m; respectively placing a coating impedance sensor at 3 points; various parameter changes under the long-term monitoring heat preservation, judge the state of coating and metal body under the heat preservation, the test result is as follows:
temperature and humidity monitoring result
The change curve of the temperature and the humidity under the heat-insulating layer along with the time within 1 year is shown in figure 5, wherein a represents the temperature, and b represents the relative humidity, and the result shows that the temperature change in the heat-insulating layer is not large within 1 year, the annual average temperature is about 8-10 ℃, and the relative humidity is lower than 50 percent, which shows that the heat-insulating layer has good effect, and the condition that the condensed water is condensed because the water vapor enters the heat-insulating layer due to heat insulation damage does not occur.
(II) results of monitoring corrosion resistance of coating
The change curve of the resistance value along with the time is shown in figure 6, 3 points (c, d and e respectively) are arranged in the heat preservation layer to monitor the resistance change of the coating, and the 3 points have the resistance values of 2 multiplied by 106Ω-2.5×106The coating keeps good corrosion resistance within the range of omega without obvious change, and the complete protection of the heat-insulating layer is indirectly verified.
(III) Corrosion Current monitoring results
The obtained corrosion current-time curve is shown in figure 7, the corrosion current density-time curve is shown in figure 8, the corrosion current in the heat-insulating layer is changed between 0 and 100nA, and the current density is 10-8A/cm2Magnitude of the order of magnitude, and comparing with the moderate temperature humidity-time curve in fig. 5, it is found that during the period of system shutdown maintenance, i.e. 150 + 180 days, the corrosion current and current density obviously rise, the time span of the peak area is larger, the temperature and humidity in the heat preservation layer and the corrosion current are slightly increased, and the corrosion trend is slightly increased.
According to the monitoring system for metal corrosion and coating integrity under the heat-insulating layer, the running condition of part of the frozen water pipeline is effectively monitored by introducing the monitoring system under the heat-insulating layer, and key technical guidance and reference basis are provided for a pipeline repairing scheme and a maintenance plan.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (10)
1. A metal corrosion and coating integrity monitoring system under a heat-insulating layer is characterized in that a coating and the heat-insulating layer (2) are sequentially arranged outside a pipeline (1) from bottom to top, the monitoring system comprises a corrosion sensor (3), a coating impedance monitoring sensor (4) and a monitor (5), the corrosion sensor (3) and the coating impedance monitoring sensor (4) are both arranged in the heat-insulating layer (2) and are arranged at intervals, the corrosion sensor (3) and the coating impedance monitoring sensor (4) are both electrically connected with the input end of the monitor (5),
the corrosion sensor (3) is used for collecting corrosion current information and sending the corrosion current information to the monitor, and the monitor is used for analyzing the corrosion current information and obtaining the corrosion rate of the pipeline according to the analysis result; the coating impedance monitoring sensor (4) is used for collecting electrochemical signals, and the monitor is used for analyzing the electrochemical signals and obtaining an electrochemical alternating-current impedance value according to the analysis result.
2. The system for monitoring metal corrosion and coating integrity under insulation according to claim 1, wherein the corrosion sensor (3) comprises a first protective shield (31) and a second protective shield (32) disposed opposite each other and a galvanic probe (33) disposed within the first protective shield (31) and the second protective shield (32), the galvanic probe (33) comprising a metal electrode (331) disposed opposite each other, a graphite electrode (332), and an insulating film (333) disposed between the metal electrode (331) and the graphite electrode (332).
3. The system for monitoring metal corrosion and coating integrity under a heat-insulating layer according to claim 2, wherein a circuit board (6) opposite to the galvanic probe (33) is further arranged in the first protective cover (31) and the second protective cover (32), a temperature sensor and a humidity sensor are integrated on the circuit board (6), and a distance is kept between the circuit board (6) and the galvanic probe (33).
4. The system for monitoring metal corrosion and coating integrity under insulation according to claim 2, wherein the first protective cover (31) has a plurality of openings (43) on the side surface, and the corrosion sensor (3) is provided with a first connecting wire for connecting the monitor (5).
5. The system for monitoring metal corrosion and coating integrity under a heat-insulating layer according to claim 3, wherein a positioning member (34) for fixing the circuit board (6) and the galvanic probe (33) is further disposed in the first protective cover (31) and the second protective cover (32), and at least two positioning grooves are disposed on the positioning member (34).
6. The system for monitoring metal corrosion and coating integrity under a heat-insulating layer according to claim 1, wherein the coating impedance monitoring sensor (4) comprises a support plate (41) and a boss (42) arranged on the support plate (41), the boss (42) is provided with at least two openings (43), an insulating wire is arranged in each opening (43), and the outer side surfaces of the boss (42) and the support plate (41) are both coated with coatings; and a second connecting wire (7) for connecting the monitor (5) is arranged outside the boss (42).
7. The system for monitoring metal corrosion and coating integrity under a heat insulation layer according to claim 1, wherein the monitor comprises an emission unit, a measurement unit, a data processing unit, a data storage unit, a data transmission unit, a display screen and a data conversion unit, the emission unit is used for emitting sine wave potential signals to the monitoring sensor, the monitoring sensor is used for feeding back the sine wave potential signals to obtain electrochemical signals and sending the electrochemical signals to the measurement unit, the measurement unit is used for measuring the electrochemical signals to obtain response signals, the data processing unit is used for calculating the electrochemical signals and the response signals to obtain impedance signals, and the data conversion unit is used for converting the impedance signals into a data format which can be displayed by the display screen.
8. The system of claim 1, further comprising a power module, a control mechanism, and an alarm connected to the control mechanism, wherein the control mechanism triggers the alarm to operate when the detected impedance value is below a target threshold.
9. The system of claim 8, wherein the target threshold is set to a range of 106Ω-1012Ω。
10. The system for monitoring metal corrosion and coating integrity under insulation according to claim 1, wherein the coating impedance monitoring sensors (4) are arranged in three, and the three are distributed at equal intervals along the circumferential direction of the pipeline.
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| CN112927828A (en) * | 2021-01-21 | 2021-06-08 | 深圳中广核工程设计有限公司 | Nuclear power station pipeline leakage simulation test system and method |
| CN113834865A (en) * | 2021-09-07 | 2021-12-24 | 广州天韵达新材料科技有限公司 | Pipeline corrosion online early warning system under heat-insulating layer and preparation method thereof |
| CN113984638A (en) * | 2021-10-29 | 2022-01-28 | 西安热工研究院有限公司 | Boiler flue gas side corrosion detection method based on alternating-current impedance |
| CN116952818A (en) * | 2023-07-19 | 2023-10-27 | 中核核电运行管理有限公司 | Method and device for monitoring corrosion of pipeline under heat preservation layer based on distributed fuses |
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