CN115906676A - Abrasion evaluation test method, abrasion evaluation test system, electronic device, and storage medium - Google Patents
Abrasion evaluation test method, abrasion evaluation test system, electronic device, and storage medium Download PDFInfo
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Abstract
The invention discloses an abrasion evaluation test method and system, wherein the method comprises the following steps: A. constructing a simulation test pipeline for simulating the pipeline abrasion degree under different working conditions in the same test loop; B. collecting the fluid flow rate, the solid particle concentration and the solid particle size of a part to be detected in a test pipeline, and pipeline material and structure data, and calculating the abrasion rate of the part to be detected; C. calculating the residual wall thickness of the abraded pipe wall according to the wall thickness of the pipeline and the abrasion rate; D. calculating dynamic deposition indexes of the solid particles according to the instantaneous speeds of the solid particles at different positions in the test pipeline, the wall surface shear stress of the pipeline wall, and distribution data of a temperature field, a pressure field and a concentration field; E. and (4) evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate, the residual wall thickness of the abrasion pipe wall and the dynamic deposition indexes of the solid particles. The method can realize the comparative evaluation of the abrasion conditions of the pipelines in service under different working conditions, and has good abrasion trend prediction accuracy, strong universality and high execution efficiency.
Description
Technical Field
The invention relates to the technical field of petrochemical industry, in particular to an abrasion evaluation test method and system for an oil pipeline, electronic equipment and a storage medium.
Background
The catalyst is applied to a plurality of important petroleum processing processes, the chemical reaction can be accelerated by adopting the proper catalyst, the product cost is reduced, but the solid catalyst and the oil product form a mixed phase and flow in the device, the mechanical abrasion of the flow-state mutation part with high flow speed in the device can be particularly caused, the local metal corrosion is promoted under the combined action of a corrosion medium, and the damage to equipment and pipelines is accelerated. In addition, deterioration of the processing raw material leads to increase of solid impurities, which also causes mechanical abrasion, and brings great hidden trouble to safe production of the device.
At present, the monitoring and detection of the abrasion condition of refining and chemical equipment mainly adopt a thickness measuring method, the method is simple and convenient, and preventive protection measures can be taken on the seriously thinned part to prevent leakage. However, the thickness measuring method has several problems: (1) The method belongs to single-point detection, the selection of a detection part usually depends on the experience of technicians, and missed detection is easy to occur; (2) The thickness measurement of the high-temperature part needs to use a high-temperature probe and a high-temperature coupling agent, so that the technical and cost requirements are high, and the danger is high; (3) The future extension to the local thinning of the abrasion can only be estimated from practical and empirical use. Therefore, an abrasion evaluation technology needs to be developed for oil pipelines containing solid catalyst impurities, so that the accuracy, reliability and safety of abrasion condition monitoring and evaluation are improved.
In the prior art, a method for evaluating the abrasion of solid particles on a pipeline elbow in pneumatic transmission is used for researching and obtaining a relation curve between the abrasion rates of different collided materials and the particle incident angle; in addition, in the research of numerical simulation of pipe abrasion of liquid-solid two-phase flow in the prior art, a mathematical model of pipe abrasion is established by a numerical simulation method. Although the prior art is applied to the field of petrochemical industry, the wear behavior of a specific part is analyzed according to enterprise requirements mainly by relying on a theoretical formula and numerical simulation, a mathematical model is complex, and the simulation usually simplifies the working conditions, so that the accuracy of the result is difficult to guarantee.
Therefore, the prior related technology has reference significance for evaluating the abrasion of pipelines containing solid impurities of petrochemical devices, but lacks the technology which can realize the purposes of comparative evaluation of the abrasion conditions of pipelines in service under different working conditions and prediction of the abrasion trend, and has good accuracy, strong universality and high execution efficiency. Therefore, a process simulation test for pipelines and elbows with different sizes, different working conditions and different materials under the action of solid oil-containing media is needed, and abrasion degree data are acquired in the process so as to establish an internal abrasion evaluation test method for the solid oil-containing pipelines.
The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
Disclosure of Invention
The invention aims to provide an abrasion evaluation test method and an abrasion evaluation test system, which can realize the comparative evaluation of the abrasion conditions of the in-service pipelines under different working conditions, and have the advantages of good abrasion trend prediction accuracy, strong universality and high execution efficiency.
To achieve the above object, according to a first aspect of the present invention, there is provided an abrasion evaluation test method comprising the steps of: A. constructing a simulation test pipeline for simulating the pipeline abrasion degree under different working conditions in the same test loop; B. collecting the fluid flow rate, the solid particle concentration and the solid particle size of a part to be detected in a test pipeline, and pipeline material and structure data, and calculating the abrasion rate of the part to be detected; C. calculating the residual wall thickness of the abrasion pipe wall according to the wall thickness of the pipeline and the abrasion rate; D. calculating dynamic deposition indexes of the solid particles according to the instantaneous speeds of the solid particles at different positions in the test pipeline, the wall surface shear stress of the pipeline wall, and distribution data of a temperature field, a pressure field and a concentration field; E. and (4) evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate, the residual wall thickness of the abrasion pipe wall and the dynamic deposition indexes of the solid particles.
Further, in the above technical solution, the erosion rate in step B may be obtained by an erosion rate calculation model, the fluid flow rate, the solid particle concentration, the solid particle size, and the pipeline material and structure data are used as characteristic parameters input by the erosion rate calculation model, and the characteristic parameters may be selected as follows: collecting process production data, material analysis and assay data and pipeline wall thickness data of an oil product pipeline containing solid particles, and performing time-space synchronization, quantitative description, error elimination and normalization pretreatment on the data; and selecting characteristic parameters through calculation and correlation analysis according to the preprocessing result. The correlation analysis may employ a correlation coefficient method.
Further, in the above technical solution, the calculation formula of the abrasion rate is as follows:
R＝α 1 V 3 +α 2 C 3 +α 3 D 3 +β 1 V 2 +β 2 C 2 +β 3 D 2 +β 4 A 2 +γ 1 V+γ 2 C+γ 3 D+γ 4 A+γ 5 formula (1) M + θ;
wherein, R is the abrasion rate, V is the fluid flow rate, C is the solid particle concentration, D is the solid particle size, A is the pipeline bending diameter ratio, and M is the quantitative description index of the pipeline material; α, β, γ, and θ are coefficients of formula (1), and the coefficients can be determined by regression fitting.
Further, in the above technical solution, the calculation method of the residual wall thickness of the abrasion tube wall is as follows:
setting the latest time for measuring the thickness of the pipe wall as t 1 Calculating t by equation (1) 1 Erosion Rate R of time t1 (ii) a Calculating the erosion Rate R at the present time t by the formula (1) t ；
Passing through t 1 Time-of-day pipeline wall thickness H, current time-of-day erosion Rate R t And t 1 Temporal erosion Rate R t1 Calculating to obtain the residual wall thickness H of the abraded pipe wall L The calculation formula is as follows:
furthermore, in the above technical scheme, the residual wall thickness H of the pipe wall can be abraded by screening L To obtain the remaining life of the pipeline.
Further, in the above technical scheme, the distribution data of the instantaneous speed of the solid particles, the wall shear stress of the pipe wall, the temperature field, the pressure field and the concentration field at different positions in the step D can be obtained by flow field simulation software.
Further, in the above technical solution, the dynamic deposition index may include a dynamic deposition rate, a deposition amount, and a deposition thickness of the solid particles; the dynamic deposition rate is a particle deposition rate W 1 Rate of exfoliation from particles W 2 A difference of (d); particle deposition rate W 1 The calculation formula of (2) is as follows:
particle exfoliation Rate W 2 The calculation formula of (2) is as follows:
where u is the fluid velocity, ρ 0 Is the particle density, u 0 Is the instantaneous abrasion velocity, m f Is particle deposition per unit areaMass, delta f Is the linear expansion coefficient of the sedimentary deposit, Δ T is the difference between the wall temperature of the pipe wall and the fluid temperature, ρ is the fluid density, μ is the dynamic viscosity of the fluid, D is the particle size, g is the gravitational acceleration.
Further, in the above technical solution, the simulation test pipeline in step a may be constructed by retrieving a corresponding structure in the physical structure twin model library.
According to a second aspect of the present invention, there is provided an abrasion evaluation test system comprising: the pipeline construction unit is used for constructing simulation test pipelines and simulating the pipeline abrasion degree under different working conditions in the same test loop; the abrasion rate acquisition unit is used for acquiring the fluid flow rate, the solid particle concentration and the solid particle size of a part to be detected in the test pipeline as well as the pipeline material and structure data, and calculating the abrasion rate of the part to be detected; the residual wall thickness acquisition unit is used for calculating the residual wall thickness of the abrasion pipe wall according to the pipe wall thickness and the abrasion rate; the dynamic deposition index acquisition unit is used for calculating the dynamic deposition index of the solid particles according to the instantaneous speed of the solid particles at different positions in the test pipeline, the wall surface shear stress of the pipeline wall, and the distribution data of the temperature field, the pressure field and the concentration field; and the qualitative evaluation unit is used for evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate, the residual wall thickness of the abrasion pipe wall and the dynamic deposition indexes of the solid particles.
Further, in the above technical scheme, the solid particle concentration, the solid particle size, and the pipeline material and structure data can be collected by the abrasion sensor group; the set of abrasion sensors includes, but is not limited to, ferromagnetic grit detection sensors, particle size distribution meters, microscopic image meters, and thickness meters.
According to a third aspect of the invention, there is provided an electronic device comprising: at least one processor; and a memory communicatively coupled to the at least one processor; wherein the memory stores instructions executable by the at least one processor to cause the at least one processor to perform the abrasion evaluation test method as previously described.
According to a fourth aspect of the present invention, there is provided a non-transitory computer readable storage medium having stored thereon computer executable instructions for causing a computer to execute the abrasion evaluation test method as described above.
Compared with the prior art, the invention has one or more of the following advantages:
1) The abrasion evaluation test method can construct the test pipeline by adjusting the corresponding structure in the physical structure twin model library, so that the pipeline construction for abrasion evaluation is more convenient and faster; the circulating pipeline part built by the method can comprise pipelines with different pipe diameters, reducing joints and elbows with different sizes in the same test loop, can be assembled into test pipelines with different conditions according to test requirements, and can comparatively inspect the abrasion degree and the abrasion characteristics of different pipe diameters and different flow rates;
2) The abrasion rate influencing factors are selected by adopting the correlation analysis of a data set, and the selected characteristic parameters are more closely related to the abrasion rate, so that the final calculation result of the abrasion rate is more accurate; through the orthogonal abrasion test of the fixed characteristic parameters, the functional relation between the characteristic parameters and the abrasion rate is simplified, and the calculation efficiency can be greatly improved; the dynamic particle deposition calculation adopts the difference value between the particle deposition rate and the particle peeling rate as a dynamic deposition index, so that the simulation of the dynamic deposition rate, the deposition amount and the deposition thickness is more accurate, and favorable quantitative conditions are created for the evaluation of the abrasion risk grade and the abrasion high-risk part;
3) The sample storage and pretreatment part in the simulation test pipeline can provide a required solid-liquid phase mixture for a downstream circulating pipeline, so that the safety and effectiveness of the test are ensured, and meanwhile, the particle size of solid particles can be screened, so that different test conditions are realized; the reducing of the circulating pipeline part, the arrangement of the elbow and the adjustable horizontal inclination angle and vertical inclination angle of the pipeline can simulate actual production pipelines with different working conditions and different pipeline sizes in the same test loop; the technology has good universality, strong flexibility and high operation efficiency;
4) The two groups of sensors and the combination use of the sensors of each group of sensors can realize the full coverage of the measurement of the index data to be measured, and can provide sufficient original data support for the subsequent abrasion evaluation calculation;
5) The method can be applied to the abrasion evaluation of the oil pipeline in service under the oil system environment containing solid impurities in the field of petrochemical industry, a test pipeline is built by simulating the actual conditions on site, the abrasion process of the complex solid-liquid system to the pipeline is monitored in situ, the actual fluid condition in the pipeline is reduced, and the result accuracy is high; qualitative and quantitative analysis of abrasion and prediction and early warning of abrasion risk can be realized. Can provide scientific basis for improving production safety monitoring and early warning level.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood and to make the technical means implementable in accordance with the contents of the description, and to make the above and other objects, technical features, and advantages of the present invention more comprehensible, one or more preferred embodiments are described below in detail with reference to the accompanying drawings.
Drawings
FIG. 1 is a schematic flow chart of an abrasion evaluation test method according to example 1 of the present invention;
fig. 2 is a schematic connection diagram of a simulation test pipeline according to embodiment 2 of the present invention.
FIG. 3 is a schematic block diagram of an abrasion evaluation test system according to example 3 of the present invention.
Fig. 4 is a schematic diagram of a hardware structure of an electronic device according to embodiment 6 of the present invention.
Detailed Description
The following detailed description of the present invention is provided in conjunction with the accompanying drawings, but it should be understood that the scope of the present invention is not limited to the specific embodiments.
Throughout the specification and claims, unless explicitly stated otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element or component but not the exclusion of any other element or component.
Spatially relative terms, such as "below," "lower," "upper," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element or feature in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the object in use or operation in addition to the orientation depicted in the figures. For example, if the article in the drawings is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the elements or features. Thus, the exemplary term "below" can encompass both an orientation of below and above. The articles may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative terms used herein should be interpreted accordingly.
In this document, the terms "first", "second", etc. are used to distinguish two different elements or portions, and are not used to define a particular position or relative relationship. In other words, the terms "first," "second," etc. may also be interchanged with one another in some embodiments.
The method, system, electronic device, and storage medium of the present invention are described in greater detail below by way of specific embodiments, it being understood that the embodiments are exemplary only and that the invention is not limited thereto.
Example 1
As shown in fig. 1, example 1 of the present invention is an abrasion evaluation test method example, including the steps of:
and S101, constructing a simulation test pipeline for simulating the pipeline abrasion degree under different working conditions in the same test loop.
The simulation test line (i.e., the actual line of the test) of the present embodiment includes a sample storage and pretreatment section and a circulation line section. The sample storage and pretreatment part is used for storing and mixing a test solid sample and an oil sample, performing solid-liquid separation on the sample after reaction, performing self-cleaning on a test pipeline, adjusting process parameters of the test mixed sample and the like. The circulating pipeline part can comprise pipelines with different pipe diameters, reducing joints and elbows with different sizes, a sample outlet valve, a waste outlet valve, a pressure control valve and the like in the same test loop, can be assembled into test pipelines with different conditions according to test requirements, and can comparatively inspect the abrasion characteristics of different pipe diameters and different flow rates. The simulation test pipeline can be constructed by taking a corresponding structure in the physical structure twin model library, namely, a corresponding pipeline physical structure twin model is selected according to the physical structure twin model library and the circulating pipeline assembly instruction.
And S102, acquiring the fluid flow rate, the solid particle concentration and the solid particle size of the part to be detected in the test pipeline in the step S101, and the pipeline material and structure data, and calculating the abrasion rate of the part to be detected.
In this step, the influence factors of the abrasion rate (i.e., the characteristic parameters input by the abrasion rate calculation model) are obtained by first performing screening of the influence factors of the abrasion rate, i.e., correlation analysis after the collection and preprocessing of raw data.
The first step of screening (i.e. collection and pre-processing of data, building a pre-set data set): establishing a preset data set to collect process production data, material analysis and assay data and pipeline wall thickness data of the oil product pipeline containing solid impurities, and performing time-space synchronization, quantitative description, gross error elimination and normalization pretreatment on the data. The time-space synchronization means that when the monitoring frequency and the time scale of the process production data, the material analysis and test data and the pipeline wall thickness data are inconsistent, the data set is supplemented according to the minimum time scale, and when the monitoring positions are inconsistent, the process production data and the material analysis and test data which are closest to the pipeline thickness measuring point are classified into the process production data and the material analysis and test data of the thickness measuring point by taking the pipeline thickness measuring point as a reference. The quantization description means that when partial data adopts non-quantization description, the non-quantization description is converted into a quantization integer i (i = 1-N) according to the total number N of non-quantization states in the data set; for example, if the material of the pipeline P1 is carbon steel, the material of the pipeline P2 is 316L stainless steel, and the unquantized total number of states N =2, the quantifiable description is that the material of the pipeline P1 is 1 and the material of the pipeline P2 is 2. Gross error rejection refers to the process of judging suspicious data and significantly different data by adopting a statistical G test and/or an F test and/or a T test, and removing or retaining the suspicious data and the significantly different data by combining the experience of a person skilled in the art. Normalization means that for each type of data, the maximum value and the minimum value are selected, and the data are transformed into the range of 0-1 through a linear method.
Second step of screening (i.e. correlation analysis): the preset data sets are two three-dimensional data sets, the first data set is a pipeline wall thickness data set corresponding to different time and different space, the second data set is a non-pipeline wall thickness data set corresponding to different time and different space, and the correlation between each kind of data in the second data set and the data in the first data set is calculated. Preferably, but not by way of limitation, the correlation analysis may employ a correlation coefficient method, defining a correlation coefficient γ, extracting data types that correlate to moderate and above wall thicknesses of the pipeline, determined as contributing factors to the erosion rate. Namely:
when the gamma is more than 0.95, the f and g type data are in significance correlation, the closer the gamma is to 1, the closer the variables f and g are to a linear functional relation; when the gamma is more than or equal to 0.8, the f and g type data are highly correlated; when 0.5. Ltoreq. Gamma. Ltoreq.0.8, f and g type data are moderately correlated. By analyzing the above correlation degree, the obtained abrasion rate influencing factors are the fluid flow rate, the solid particle concentration, the solid particle size, the pipeline material and the structure, wherein the pipeline material is linearly related to the pipeline wall thickness.
In this step, after obtaining the influence factors of the erosion rate, an orthogonal erosion test of the aforementioned characteristic variables is performed, and the amount of erosion in the time t period is measured to establish the functional relationship between the erosion rate and each influence factor. Namely, the same test loop is formed by matching pipelines with different pipe diameters and pipe fittings, so that the flow rate can be changed independently; the same test loop is formed by matching pipelines and pipe fittings made of different materials, so that the material of the pipelines can be changed independently; the same test loop is formed by matching pipelines with the same pipe diameter and elbows with different bending ratios, so that the structure of the pipelines is changed independently; the feeding of the same test loop controls different solid concentrations to realize the independent change of the solid particle concentration; the feeding of the same test loop controls different solid particle sizes, and the independent change of the solid particle sizes is realized. According to the correlation analysis results, fitting the abrasion rate R with the fluid flow velocity V, the solid particle concentration C, the solid particle diameter D, the bending ratio A and the material M (which is quantified). That is to say that the first and second electrodes,
R＝a 1 V 3 +b 1 V 2 +c 1 V+d 1
R＝a 2 C 3 +b 2 C 2 +c 2 C+d 2
R＝a 3 D 3 +b 3 D 2 +c 3 D+d 3
R＝a 4 A 2 +b 4 A+c 4
R＝a5M
wherein, R and M are unitary function relation, R and A are binary function relation, and R and V, C and D are ternary function relation.
In this step, the calculation formula defining the erosion rate of the pipe line as a function of the erosion rate and the respective influencing factors is as follows:
R＝α 1 V 3 +α 2 C 3 +α 3 D 3 +β 1 V 2 +β 2 C 2 +β 3 D 2 +β 4 A 2 +γ 1 V+γ 2 C+γ 3 D+γ 4 A+γ 5 formula (1) M + θ;
wherein R is the abrasion rate, V is the fluid flow rate, C is the solid particle concentration, D is the solid particle size, A is the pipeline bending diameter ratio, and M is the quantitative description index of the pipeline material; alpha, beta, gamma and theta are coefficients of formula (1), and these coefficients can be determined by regression fitting, i.e. by developing several abrasion tests under different conditions to obtain the abrasion rates under different characteristic parameters of influencing factors, and the regression fitting determines the coefficients in the calculation formula of the abrasion rates.
Further, the method can be used for preparing a novel liquid crystal displayIn the step, the fluid flow speed, the solid particle concentration, the solid particle size, the bend ratio and the pipeline material of the solid-containing oil pipeline at the current time t are obtained, the characteristic parameters are input into the formula (1) of the abrasion rate calculation model, and the abrasion rate R is obtained t 。
And step S103, calculating the residual wall thickness of the abraded pipe wall according to the pipe wall thickness and the abrasion rate.
Specifically, the latest time for measuring the thickness of the pipe wall can be set as t 1 Calculating t by the aforementioned formula (1) 1 Erosion Rate R of time t1 . Passing through t 1 Wall thickness H of pipeline at time, erosion Rate R at Current time t t And t 1 Temporal erosion Rate R t1 Calculating to obtain the residual wall thickness H of the abraded pipe wall L The calculation formula is as follows:
further, the wall thickness H of the pipe wall can be abraded by screening L The remaining life S of the pipeline is obtained.
I.e. the remaining life of the pipeline
And step S104, calculating the dynamic deposition index of the solid particles by testing the instantaneous speed of the solid particles at different positions in the pipeline, the shearing stress of the wall surface of the pipeline wall, and the distribution data of the temperature field, the pressure field and the concentration field.
Firstly, simulation calculation is carried out on the instantaneous speed of solid particles at different positions in a test pipeline, the wall surface shear stress of a pipe wall, and the distribution data of a temperature field, a pressure field and a concentration field through flow field simulation software. For example, by using software with a flow field simulation function, such as CPFD Barracuda, FLUENT, etc., on the basis of a pipeline structured grid model, boundary conditions, such as temperature, pressure, flow rate, liquid flow, solid particle concentration, particle morphology, particle size, pipe wall material, etc., are input, and output results including instantaneous velocity of solid particles, pipe wall shear stress, temperature field, pressure field, concentration field distribution, etc., can be obtained.
And secondly, calculating the dynamic deposition index of the solid particles through the related data acquired by the flow field simulation software. The dynamic process of deposition and stripping of particles on the wall surface can be simulated by comprehensively considering the action of the flow field. In the prior art, there are other calculation methods of deposition rate in application scenarios, but the dynamic process of deposition and stripping is considered comprehensively in this embodiment, and the dynamic process of solid particle deposition is described by the difference between the deposition rate and the stripping rate, so that the dynamic deposition index can be calculated more accurately.
Specifically, W (dynamic deposition rate) = W1 (deposition rate) -W2 (peeling rate), W1 and W2 may be calculated by the output data of the aforementioned flow field simulation software, and then the dynamic deposition rate W is obtained.
Rate of particle deposition
Rate of particle exfoliation
Where u is the fluid velocity, ρ 0 Is the particle density, u 0 Is the instantaneous abrasion velocity, m f Is the mass of particle deposition per unit area, δ f Is the linear expansion coefficient of the deposit (delta may be used) f = 1). Δ T is the difference between the wall temperature of the pipe wall and the fluid temperature, ρ is the fluid density, μ is the dynamic viscosity of the fluid, D is the particle size, and g is the acceleration of gravity.
Dynamic deposition rate W = W 1 -W 2
Further, let the mass of the scale formed in unit area at the current time t be m t The deposition amount at time t + Δ t can be calculated by the following equation:
the wall deposit thickness at time t + Δ t can be calculated by:
and step S105, evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate obtained in the step S102, the residual wall thickness of the abrasion tube wall obtained in the step S103 and the dynamic deposition index of the solid particles obtained in the step S104. The risk level may be defined based on experience and business safety requirements and may preferably, but not exclusively, be graded in terms of the magnitude of the erosion rate, or in terms of the magnitude of the remaining life of the pipe, or in terms of the minimum wall thickness in comparison to a design specification minimum. The high-abrasion part can be comprehensively judged by the wall shear stress output by flow field simulation software and the deposition thickness or deposition amount output by dynamic particle deposition calculation, and the abrasion risk of the part is higher when the wall shear stress is larger and the deposition thickness (or deposition amount) is smaller.
The abrasion evaluation test method can construct the test pipeline by adjusting the corresponding structure in the physical structure twin model library, so that the pipeline construction for abrasion evaluation is more convenient and faster; the circulating pipeline part built by the method can comprise pipelines with different pipe diameters, reducing joints and elbows with different sizes in the same test loop, can be assembled into test pipelines with different conditions according to test requirements, and can comparatively inspect the abrasion degrees and the abrasion characteristics of different pipe diameters and different flow rates; the abrasion rate influencing factors are selected by adopting the correlation analysis of a data set, and the selected characteristic parameters are more closely related to the abrasion rate, so that the final calculation result of the abrasion rate is more accurate; through the orthogonal abrasion test of the fixed characteristic parameters, the functional relation between the characteristic parameters and the abrasion rate is simplified, and the calculation efficiency can be greatly improved; the dynamic particle deposition calculation adopts the difference value of the particle deposition rate and the particle peeling rate as a dynamic deposition index, so that the simulation of the dynamic deposition rate, the deposition amount and the deposition thickness is more accurate, and favorable quantitative conditions are created for the evaluation of the abrasion risk grade and the abrasion high-risk part.
Example 2
This example 2 is a simulation test line (i.e., an actual line for testing) referred to in example 1. The test line (which may also be referred to as a test stand) includes a sample storage and pretreatment section and a circulation line section.
Specifically, referring to FIG. 2, the sample storage and pretreatment portions are schematically connected to each device. Wherein, experimental solid sample is saved in solid sample storage jar 11 with solid sample, and experimental oil liquid sample is saved in oil storage jar 12 with oil. The bottom of the solid sample storage tank 11 and the bottom of the oil storage tank 12 are both funnel-shaped, a stirrer 112 is arranged in the storage tank, the sample storage tank is connected and guided to the mixing buffer tank 14 through a drainage tube and a valve, the valve is an automatic control valve 113, and the opening of the valve can be controlled according to the solid-liquid ratio of logistics in an actual device. The temperature control device 18 is arranged in the oil storage tank 12, so that the oil sample can be prevented from having too high viscosity and being difficult to flow out.
As further shown in fig. 2, a plurality of layers of detachable filter sieve plates 114 with different pore sizes are arranged in the solid sample storage tank 11, and can be opened or closed under the control of the controller, so as to automatically adjust the particle size of the solid sample as required. A heating and insulating layer 115 is arranged outside the drainage pipe of the oil product storage tank 12, so that the blockage of the drainage pipe due to small inner diameter of the drainage pipe, high oil viscosity and low temperature is prevented.
As further shown in fig. 2, a temperature control device 18 and a safety valve 111 are disposed in the mixing buffer tank 14 and connected to the pump 17, and a pressure regulating device 19 is disposed in the pump 17, and after uniform mixing and actual working conditions are achieved, the mixed sample is sent to the circulation pipeline portion under the driving of the pump 17. The relief valve 111 is used to prevent a runaway fault in the temperature control device 18. The oil-solid separator 15 has a heating function to prevent the viscosity of the sample from being too high to lower the separation efficiency. The solid outlet of the oil-solid separator 15 is connected with the solid sample storage tank 11, and the oil outlet is connected with the oil storage tank 12. The cleaning agent storage tank 13 and the purge gas tank 16 are connected to the mixing buffer tank 14, and the cleaning agent enters the circulation line portion, passes through the waste outlet, and recovers the cleaning waste liquid to the waste tank 110. And a purging step is executed after cleaning, so that a self-cleaning function is realized. The purge gas is preferably dry nitrogen.
With further reference to fig. 2, the circulating pipeline portion includes pipelines 31 with different pipe diameters, reducer joints 32 and elbows 33 with different sizes, a sample outlet valve 34, a waste outlet valve 35 and a pressure control valve 36. Two ends of the circulating pipeline part are respectively connected with the pump 17 and the pressure control valve 36 through hoses 37, the outlet of the circulating pipeline is divided into two branches, one branch is connected with the oil-solid separator 15, and a sample outlet valve 34 is arranged on the branch; the other path is connected to a canister 110, which is provided with a waste outlet valve 35.
Further, in order to realize the support of the circulating pipeline and simultaneously realize the lifting, the inclination and the rotation of the pipeline and the elbow, the circulating pipeline part is provided with a corresponding support system. The supporting system (not shown in the figure) comprises a bracket capable of lifting up and down, a base, a hoop, a slide rail, a movable sling, a positioning and leveling measuring device, a power mechanism and the like. The slide rails are divided into two groups of X slide rails and Y slide rails which are vertically crossed and fixed on the base through rollers, and the slide rails can slide on the base under the driving of the rollers to adapt to pipelines with different lengths and assist in realizing different horizontal inclinations. The support is arranged on the sliding rail, the test pipeline is arranged on the support and is locked by the hoop to prevent movement, and the support can move along the sliding rail under the driving of the power mechanism and is used for realizing the horizontal inclination of the test pipeline. The movable sling is connected above the support, the sling can be lifted up and down under the driving of the power mechanism to drive the support to realize the vertical inclination of the test pipeline, and the lifting height can be set and regulated by a corresponding controller. The positioning and leveling measuring device is used for accurately measuring the actual inclination angle of the pipeline. The bracket can also be provided with a position adjusting knob which can be manually and quickly roughly adjusted to the position and the inclination angle of the test pipeline. Through the supporting system of the circulating pipeline part, the horizontal inclination angle and the vertical inclination angle of the circulating pipeline can be quickly adjusted, and the pipeline form of the real production condition under different working conditions can be conveniently simulated by using the same test loop.
Further, in the supporting system of the sample storage and pretreatment part and the circulation pipeline part according to this embodiment, the aforementioned components to be controlled by the controller are controlled by parallel branches, the control system is provided with a control port for sending out a drive control command and a wired/wireless connection module for receiving signal feedback, and the control system may be provided with a control panel and a display screen for inputting and outputting data. The control panel is movable, is provided with a remote control module and can transmit data with the control port through Bluetooth, and when the movement of the support system and the circulation pipeline part is controlled or the working condition is harsh and dangerous, a tester can carry the control panel to be far away from the test bed and enter a safe area for control.
With further reference to fig. 2, two sensor sets are provided at the portion of the circulation line section to be measured. One of which is a set of condition sensors 41 for monitoring process parameters and the other of which is a set of abrasion sensors 42 for in situ monitoring of the abrasion process. The working condition sensor group 41 is arranged in the mixing buffer tank 14 of the sample storage and pretreatment part and behind the pump 17, and comprises a temperature sensor, a pressure sensor, a flow meter, a flow speed measuring instrument and the like which can monitor temperature, pressure, flow and flow speed parameters in real time. The abrasion sensor group 42 is used for monitoring the abrasive particle concentration, the abrasive particle size distribution of the abrasive particles and solid particles in the test sample, and the abrasion morphology and the wall thickness of the inner wall surface of the pipeline in real time, and can provide raw data for the calculation related to the embodiment 1 of the invention. The abrasion sensor group 42 may include ferromagnetic abrasive particle detection sensors, particle size distribution measuring instruments, microscopic image measuring instruments, thickness gauges, and the like. Further, the abrasion sensor group 42 further has an optical element capable of detecting an opaque logistics system, so as to meet the visualization requirement of a dark color sample in a closed pipeline, and the abrasion sensor group 42 has the functions of dynamic video acquisition and video recording. The abrasion sensor group 42 can also be connected to the aforementioned control system, by which the sensor measurement parameters are set and the sensor probe position can be changed by the controller of the control system for obtaining optimum measurement accuracy and visualization. The two sensor groups are provided with wireless transmission modules and wired interfaces, original measurement data can be provided for the calculation model related to the embodiment 1 of the invention in a wireless or wired mode, and meanwhile, the local storage module is configured, so that historical monitoring original data can be stored and backed up.
The sample storage and pretreatment part in the simulation test pipeline can provide a required solid-liquid phase mixture for a downstream circulating pipeline, so that the safety and effectiveness of the test are ensured, and meanwhile, the particle size of solid particles can be screened, so that different test conditions are realized; the reducing of the circulating pipeline part, the arrangement of the elbow and the adjustable horizontal inclination angle and vertical inclination angle of the pipeline can simulate actual production pipelines with different working conditions and different pipeline sizes in the same test loop. The two groups of sensors and the combination of the sensors in each group of sensors can realize the full coverage of the measurement of the index data to be measured, and can provide sufficient original data support for the subsequent abrasion evaluation calculation.
Example 3
As shown in fig. 3, this example 3 is an example of an abrasion evaluation test system. Comprises a pipeline construction unit 201, an abrasion rate acquisition unit 202, a residual wall thickness acquisition unit 203, a dynamic deposition index acquisition unit 204 and a qualitative evaluation unit 205. The pipeline constructing unit 201 is used for constructing a simulation test pipeline, and can simulate the pipeline abrasion degree under different working conditions in the same test loop. Preferably, but not limitatively, the simulation test pipeline can be constructed by retrieving corresponding structures in the physical structure twin model library. The erosion rate obtaining unit 202 is configured to collect a fluid flow rate, a solid particle concentration, a solid particle size, and a pipeline material and structure data of a portion to be measured in the test pipeline, and calculate an erosion rate of the portion to be measured. The residual wall thickness obtaining unit 203 is used for calculating the residual wall thickness of the abraded pipe wall according to the pipe wall thickness and the abrasion rate. The dynamic deposition index obtaining unit 204 is configured to calculate a dynamic deposition index of the solid particles according to instantaneous speeds of the solid particles at different positions in the test pipeline, wall shear stress of the pipeline wall, and distribution data of the temperature field, the pressure field, and the concentration field. The qualitative assessment unit 205 performs assessment of the abrasion risk level and the abrasion high-risk portion according to the abrasion rate, the residual wall thickness of the abraded pipe wall and the dynamic deposition index of the solid particles.
Example 4
The present embodiments provide a non-transitory (non-volatile) computer storage medium having stored thereon computer-executable instructions that can perform the erosion evaluation test method of any of the method embodiments described above, and achieve the same technical effects.
Example 5
The present embodiment provides a computer program product comprising a computer program stored on a non-transitory computer-readable storage medium, the computer program comprising program instructions that, when executed by a computer, cause the computer to perform the abrasion evaluation test method described in the above aspects, and achieve the same technical effects.
Example 6
Fig. 4 is a schematic diagram of the hardware configuration of the abrasion evaluation test electronic device according to the present embodiment. The device includes one or more processors 610 and memory 620. Take a processor 610 as an example. The apparatus may further include: an input device 630 and an output device 640.
The processor 610, memory 620, input device 630, and output device 640 may be connected by a bus or other means.
The memory 620, which is a non-transitory computer readable storage medium, may be used to store non-transitory software programs, non-transitory computer executable programs, and modules. The processor 610 executes various functional applications and data processing of the electronic device, i.e., the processing method of the above-described method embodiment, by executing the non-transitory software programs, instructions and modules stored in the memory 620.
The memory 620 may include a storage program area and a storage data area, wherein the storage program area may store an operating system, an application program required for at least one function; the storage data area may store data and the like. Further, the memory 620 may include high speed random access memory, and may also include non-transitory memory, such as at least one magnetic disk storage device, flash memory device, or other non-transitory solid state storage device. In some embodiments, the memory 620 optionally includes memory located remotely from the processor 610, which may be connected to the processing device via a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The input device 630 may receive input numeric or character information and generate a signal input. The output device 640 may include a display device such as a display screen.
The one or more modules are stored in the memory 620 and, when executed by the one or more processors 610, perform an abrasion evaluation test method that:
constructing a simulation test pipeline for simulating the pipeline abrasion degree under different working conditions in the same test loop; collecting the fluid flow speed, the solid particle concentration and the solid particle size of a part to be detected in the test pipeline, and pipeline material and structure data, and calculating the abrasion rate of the part to be detected; calculating the residual wall thickness of the abrasion pipe wall according to the wall thickness of the pipeline and the abrasion rate; calculating the dynamic deposition index of the solid particles according to the instantaneous speed of the solid particles at different positions in the test pipeline, the wall surface shear stress of the pipeline wall, and the distribution data of the temperature field, the pressure field and the concentration field; and evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate, the residual wall thickness of the abrasion pipe wall and the dynamic deposition index of the solid particles.
The product can execute the method provided by the embodiment of the invention, and has corresponding functional modules and beneficial effects of the execution method. For technical details that are not described in detail in this embodiment, reference may be made to methods provided by other embodiments of the present invention.
The above-described embodiments of the apparatus are merely illustrative, and the units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of the present embodiment.
Through the above description of the embodiments, those skilled in the art will clearly understand that each embodiment can be implemented by software plus a general hardware platform, and certainly can also be implemented by hardware. Based on such understanding, the above technical solutions substantially or contributing to the related art may be embodied in the form of a software product, which may be stored in a computer-readable storage medium, such as ROM/RAM, magnetic disk, optical disk, etc., and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute the method according to the embodiments or some parts of the embodiments.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and its practical application to enable one skilled in the art to make and use various exemplary embodiments of the invention and various alternatives and modifications as are suited to the particular use contemplated. Any simple modifications, equivalent changes and modifications made to the above exemplary embodiments shall fall within the scope of the present invention.
Claims (13)
1. An abrasion evaluation test method characterized by comprising the steps of:
A. constructing a simulation test pipeline for simulating the pipeline abrasion degree under different working conditions in the same test loop;
B. collecting the fluid flow rate, the solid particle concentration and the solid particle size of a part to be detected in the test pipeline, and pipeline material and structure data, and calculating the abrasion rate of the part to be detected;
C. calculating the residual wall thickness of the abraded pipe wall according to the pipe wall thickness and the abrasion rate;
D. calculating the dynamic deposition index of the solid particles according to the instantaneous speed of the solid particles at different positions in the test pipeline, the wall surface shear stress of the pipeline wall, and the distribution data of the temperature field, the pressure field and the concentration field;
E. and evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate, the residual wall thickness of the abrasion pipe wall and the dynamic deposition index of the solid particles.
2. An abrasion evaluation test method according to claim 1, wherein said abrasion rate in said step B is obtained by an abrasion rate calculation model, said fluid flow rate, solid particle concentration, solid particle size and pipe material and structure data are used as characteristic parameters inputted by said abrasion rate calculation model, and said characteristic parameters are selected in the following manner:
collecting process production data, material analysis and assay data and pipeline wall thickness data of an oil pipeline containing the solid particles, and performing time-space synchronization, quantitative description, error elimination and normalization pretreatment on the data;
and selecting the characteristic parameters through calculation and correlation analysis according to the preprocessing result.
3. The abrasion evaluation test method according to claim 2, wherein the correlation analysis uses a correlation coefficient method.
4. An abrasion evaluation test method according to claim 1, wherein the calculation formula of the abrasion rate is as follows:
R＝α 1 V 3 +α 2 C 3 +α 3 D 3 +β 1 V 2 +β 2 C 2 +β 3 D 2 +β 4 A 2 +γ 1 V+γ 2 C+γ 3 D+γ 4 A+γ 5 formula (1) M + θ;
wherein R is the abrasion rate, V is the fluid flow rate, C is the solid particle concentration, D is the solid particle size, A is the pipeline bending diameter ratio, and M is the quantitative description index of the pipeline material; α, β, γ, and θ are coefficients of the formula (1), which are determined by regression fitting.
5. An abrasion evaluation test method according to claim 4, wherein the remaining wall thickness of the abrasion tube wall is calculated as follows:
setting the latest time for measuring the thickness of the pipe wall as t 1 Calculating t by said formula (1) 1 Temporal erosion Rate R t1 (ii) a Calculating the abrasion rate R at the present time t by said formula (1) t ；
Passing through t 1 Wall thickness H of pipeline at time, erosion Rate R at Current time t t And t 1 Temporal erosion Rate R t1 Calculating to obtain the residual wall thickness H of the abraded pipe wall L The calculation formula is as follows:
6. an abrasion evaluation test method according to claim 5, wherein said abrasion tube wall residual wall thickness H is selected by screening L Obtaining the remaining life of the pipeline.
7. An abrasion evaluation test method according to claim 1, wherein the instantaneous velocity of solid particles at different positions, the wall shear stress of the pipe wall, and the distribution data of the temperature field, the pressure field and the concentration field in step D are obtained by flow field simulation software.
8. An abrasion evaluation test method according to claim 1, wherein said dynamic deposition index includes a dynamic deposition rate, a deposition amount, and a deposition thickness of solid particles; the dynamic deposition rate is a particle deposition rate W 1 Rate of exfoliation from particles W 2 A difference value of (a);
the particle deposition rate W 1 The calculation formula of (2) is as follows:
the particle peeling rate W 2 The calculation formula of (2) is as follows:
where u is the fluid velocity, ρ 0 Is the particle density, u 0 Is the instantaneous abrasion velocity, m f Is the mass of particle deposition per unit area, δ f Is the coefficient of linear expansion of the deposit, Δ T is the difference between the wall temperature of the tube wall and the fluid temperature, ρ is the fluid density, μ is the dynamic viscosity of the fluid, D is the particle size, and g is the gravitational acceleration.
9. An abrasion evaluation test method according to claim 1, wherein said simulation test line in step a is constructed by retrieving a corresponding structure in a physical structure twin model library.
10. An abrasion evaluation test system, comprising:
the pipeline construction unit is used for constructing simulation test pipelines and simulating the pipeline abrasion degree under different working conditions in the same test loop;
the abrasion rate acquisition unit is used for acquiring the fluid flow rate, the solid particle concentration and the solid particle size of a part to be detected in the test pipeline and the pipeline material and structure data, and calculating the abrasion rate of the part to be detected;
the residual wall thickness acquisition unit is used for calculating the residual wall thickness of the abrasion pipe wall according to the pipe wall thickness and the abrasion rate;
the dynamic deposition index acquisition unit is used for calculating the dynamic deposition index of the solid particles according to the instantaneous speed of the solid particles at different positions in the test pipeline, the shearing stress of the wall surface of the pipeline wall, the distribution data of the temperature field, the pressure field and the concentration field;
and the qualitative evaluation unit is used for evaluating the abrasion risk grade and the abrasion high-risk part according to the abrasion rate, the residual wall thickness of the abrasion pipe wall and the dynamic deposition index of the solid particles.
11. An abrasion evaluation test system according to claim 10, wherein said solid particle concentration, solid particle size and pipeline material and structure data are collected by an abrasion sensor group; the abrasion sensor group comprises a ferromagnetic abrasive particle detection sensor, a particle size distribution measuring instrument, a microscopic image measuring instrument and a thickness gauge.
12. An electronic device, comprising:
at least one processor; and
a memory communicatively coupled to the at least one processor; wherein the content of the first and second substances,
the memory stores instructions executable by the at least one processor to cause the at least one processor to perform the abrasion evaluation test method of any one of claims 1-9.
13. A non-transitory computer-readable storage medium storing computer-executable instructions for causing a computer to perform the abrasion evaluation test method according to any one of claims 1 to 9.
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| CN116660107B (en) * | 2023-04-27 | 2024-04-19 | 北京格谱检测科技有限公司 | Online wear detection anti-bubble interference method and device |
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