CN116379356A - Device and method for on-line monitoring scaling and blocking trend of inner wall of metal pipe - Google Patents

Device and method for on-line monitoring scaling and blocking trend of inner wall of metal pipe Download PDF

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Publication number
CN116379356A
CN116379356A CN202310393941.5A CN202310393941A CN116379356A CN 116379356 A CN116379356 A CN 116379356A CN 202310393941 A CN202310393941 A CN 202310393941A CN 116379356 A CN116379356 A CN 116379356A
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Prior art keywords
metal pipe
probe
wall
pipeline
trend
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祁晓牧
曲广军
万兴华
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Guizhou Hetaida Technology Co ltd
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Guizhou Hetaida Technology Co ltd
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Priority to CN202310393941.5A priority Critical patent/CN116379356A/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17DPIPE-LINE SYSTEMS; PIPE-LINES
    • F17D5/00Protection or supervision of installations
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/24Preventing accumulation of dirt or other matter in the pipes, e.g. by traps, by strainers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Investigating Or Analyzing Materials By The Use Of Electric Means (AREA)

Abstract

The invention discloses a device and a method for on-line monitoring of scaling and blocking trend of inner wall of a metal pipe, comprising a micro-resistance measuring instrument, a round inspection controller, a segmented pipeline conductive metal probe and a measuring loop wire, wherein the segmented pipeline conductive metal probe comprises an outer probe and an inner probe, one end of the inner probe is inserted into the center of the metal pipe through a gap of a flange of the metal pipe, the inner probe is in good contact with the fluid in the pipe, a sealing gasket is arranged between the flanges of the metal pipe, and the inner probe is installed in a sealing way through the sealing gasket. The invention can provide data for users, intuitively reflect the scaling condition of the inner wall of each section of pipeline, and is convenient for determining whether to maintain production or directly determine that the section of pipeline needs dredging, overhauling or replacement, and carrying out operation and maintenance work with a certain vector so as to improve the production efficiency; the energy consumption is saved, the production efficiency is improved, the circuits, the elements and the equipment of the whole system are fixedly installed for one time, and the complicated moving work of the mobile monitoring equipment in other various blocking detection modes is avoided.

Description

Device and method for on-line monitoring scaling and blocking trend of inner wall of metal pipe
Technical Field
The invention belongs to the field of pipeline fluid conveying, and particularly relates to a device and a method for on-line monitoring of scaling and blocking trend of an inner wall of a metal pipe.
Background
In various industrial fields such as metallurgy, petrochemical industry, and chemical industry, there are a large number of processes for transporting liquid or slurry-like fluid substances (hereinafter referred to as "fluids") by using pipelines. The components of the fluid in the pipeline are complex, and the fluid is formed by mixing various acid/alkali/salt solutions, particle suspension materials, molten slurry, various mineral substances and the like in different processes, and has various working conditions of low temperature, normal temperature, high temperature and the like.
The length of the conveying pipeline is possible from a few meters to tens of kilometers, the pipeline is provided with a plurality of structures such as a single pipe, a calandria, a bending rotation structure and the like, and also has a sleeve structure for long-distance heat preservation and heating, the inner pipe conveys fluid, the outer pipe is filled with steam or heat-conducting fluid, and the outer pipe is wrapped with heat preservation and heat insulation materials.
The fluid in the pipe can generate more or less chemical reaction in the conveying process, and a layer of scale is gradually deposited on the inner wall of the pipeline, just like scale is generated after the kettle is used for a long time. The scale in the pipe gradually thickens, so that the inner space of the pipe is squeezed and narrowed, and the transportation of fluid in the pipe is blocked until the pipe is plugged, thereby seriously affecting the normal operation of the process. Once the pipeline is blocked, particularly a long-distance pipeline, the specific blocking position is difficult to judge, and the pipeline can be only detached and checked in a segmented and partitioned manner and dredged or replaced, so that the long-time production stopping, overhauling and maintenance workload of the whole process is huge.
For example, the core process in the alumina production factory of the aluminum smelting industry is high-temperature pipeline digestion, namely, a sleeve with the total length of more than ten kilometers is in a multi-turn bent structure, the inner tube is used for conveying slurry-like fluid composed of substances such as aluminum silicon mineral powder, naOH, ca (OH) 2 solution and the like, the outer tube is filled with steam with the temperature of more than 230 ℃, and the inner tube fluid is continuously heated. The inner tube fluid is subjected to chemical reaction in the conveying process and in a high-temperature environment, and finally Al (OH) 3 and red mud ore pulp with residual silicon and calcium substances are generated by dissolution. In the alumina pipeline digestion process, the scaling and blocking phenomenon of the inner pipe wall easily occurs in a large number of pipelines, and according to practical production experience, the new pipeline generally generates serious scaling for several months, so that the flow velocity and flow of the fluid in the pipeline are reduced, and even the pipeline is blocked and blocked. At present, an alumina plant can only adopt a mode of regular production stopping and maintenance for about 3 months, the whole pipeline is flushed by high-pressure water, scaling in the pipeline is flushed out by flushing, and a pipeline can only be disassembled in a segmented way to find a blocking point for dredging or replacement when the pipeline is seriously blocked. The method has long production stopping time, low water and energy consumption, low overhaul and maintenance efficiency, huge workload, and great manpower and material resources consumed for each maintenance.
Disclosure of Invention
In order to solve the technical problems, the invention mainly aims to provide a method and a device for measuring the comprehensive equivalent resistance of a sectional pipeline integrated substance, grasping the scale formation thickness of the inner wall of each section of pipeline through the resistance change trend, carrying out real-time on-line monitoring on a pipeline for conveying fluid, accurately grasping the scale formation change condition of the inner wall of each section of pipeline and accurately judging the position of a blocked pipeline, and aims to solve the technical problems.
The invention is realized by the following technical scheme.
The invention provides a device for on-line monitoring of scaling blocking trend of inner wall of metal tube, comprising micro resistance measuring instrument, round inspection controller, subsection pipeline conductive metal probe, measuring loop wire, wherein the subsection pipeline conductive metal probe comprises outer probe and inner probe, one end of the inner probe is inserted into the center of metal tube through metal tube flange gap, the inner probe is in good contact with inner fluid in tube, sealing gasket is arranged between metal tube flanges, the inner probe is sealed and installed through sealing gasket, the inner probe is insulated with metal tube, the outer probe is welded or well conductive connected with outer wall of metal tube, micro resistance measuring instrument is electrically connected with round inspection controller, and round inspection controller is electrically connected with subsection pipeline conductive metal probe through measuring loop wire.
The micro resistance measuring instrument sends resistance measurement data to the resistance record analysis data server through the on-site network communication equipment, the resistance record analysis data server analyzes the data through the trend model operation display and alarm interface software and generates a chart, and early warning information is sent after the resistance exceeds a set value.
The automatic monitoring device is characterized in that a plurality of groups of wheel inspection loops are arranged in the wheel inspection controller, the number of the wheel inspection loops is set according to the number of metal pipe sections to be monitored, the time sequence conduction control of the wheel inspection loops is controlled by adopting PLC (programmable logic controller) and DCS (distributed control system) automatic control equipment or by a singlechip electronic circuit board, and each wheel inspection loop independently corresponds to one section of pipeline in a control system.
One end of the measuring loop wire passes through the metal pipe flange, and a protective layer is arranged on the outer side of the measuring loop wire.
The trend model operation display and alarm interface software comprises a computer HMI interface, a mobile phone APP or applet, an analysis model database and a data transmission communication module, and is used for customizing and developing various display models and alarm measures according to different user and process requirements and developing functions of user login, authorized control and historical record inquiry.
A method for on-line monitoring the scaling and blocking trend of the inner wall of a metal pipe comprises the following steps:
step S1, installing an inner probe at the flange joint of each section of metal pipe, installing an outer probe on the outer wall of the metal pipe, and connecting the segmented pipeline conductive metal probe with a wheel inspection controller through a measuring loop wire, wherein the wheel inspection controller is connected with a micro resistance measuring instrument;
step S2, the micro-resistance measuring instrument measures resistance values of the round trip circuits one by one through an internal controller of the round trip controller, and sends measured data to a resistance value record analysis data server through on-site network communication equipment;
and S3, analyzing the resistance value data in the resistance value record analysis data server through trend model operation display and alarm interface software to generate a chart, and sending out early warning information when the resistance value exceeds a set value.
In the step S3, each section of metal pipe is fitted into a curve along a time axis according to the accumulated scale thickness parameters of the periodic time sequence, so as to form the real-time variation trend of the scale thickness.
The trend model operation display and alarm interface software customizes and develops various display models and alarm measures according to different users and process requirements, and develops functions of user login, authorized control and history record inquiry.
The invention has the beneficial effects that:
1. the user can intuitively know the scaling condition of the inner wall of each section of pipeline according to the scaling thickness trend displayed by each section of pipeline so as to determine whether to maintain production or directly determine that the section of pipeline needs dredging, overhauling or replacement, and the operation and maintenance work is carried out with a certain vector, so that the production efficiency is improved;
2. the high energy consumption and high water consumption generated by blind flushing of the whole process line can be avoided, and the sewage discharge amount is reduced;
3. the circuit, the components and the equipment of the whole system are fixedly installed for one time and for all the time, so that the complicated moving work of the mobile monitoring equipment in other various blocking detection modes is avoided;
4. the monitoring is visual, accurate, real-time, efficient and accurate to each section of physical pipeline, and fault points and hidden trouble points are implemented to the minimum range;
5. the intelligent trend prediction system can easily realize various intelligent functions such as trend prediction, early warning, emergency warning and the like, has detailed history records, and provides reliable support for factory informatization and intellectualization.
Drawings
FIG. 1 is a schematic cross-sectional view of a pipe with inner wall fouling;
FIG. 2 is a schematic diagram of the principle of equivalent resistance measurement of a pipeline;
fig. 3 is a schematic view of the overall structure of the device of the present invention.
In the figure: the system comprises a 1-micro resistance measuring instrument, a 2-round inspection controller, a 3-segmented pipeline conductive metal probe, a 4-resistance recording and analyzing data server, 5-field network communication equipment, 6-trend model operation display and alarm interface software and 7-measurement loop wires.
Detailed Description
The technical solution of the present invention is further described below, but the scope of the claimed invention is not limited to the above.
As shown in fig. 1, fig. 2 and fig. 3, the device for on-line monitoring of scaling and blocking trend of inner wall of metal tube comprises a micro resistance measuring instrument 1, a round inspection controller 2, a segmented pipeline conductive metal probe 3 and a measuring loop wire 7, wherein the segmented pipeline conductive metal probe 3 comprises an outer probe and an inner probe, one end of the inner probe is inserted into the center of the metal tube through a metal tube flange gap, the inner probe is in good contact with the inner fluid of the tube, a sealing gasket is arranged between the metal tube flanges, the inner probe is in sealing installation through the sealing gasket, the inner probe is insulated from the metal tube, the outer probe is welded or in good conductive connection with the outer wall of the metal tube, the micro resistance measuring instrument 1 is in electrical connection with the round inspection controller 2, and the round inspection controller 2 is in electrical connection with the segmented pipeline conductive metal probe 3 through the measuring loop wire 7.
The micro-resistance measuring instrument 1 and the round inspection controller 2 are arranged in a control room or a special control cabinet near a pipeline production system, the sectional pipeline conductive metal probes 3 are arranged inside and outside the sectional pipeline to be monitored in groups, and are connected with the round inspection controller 2 through a measuring loop lead 7; the round inspection controller 2 is connected with the micro resistance measuring instrument 1, so that the micro resistance measuring instrument 1 can sequentially detect the resistance value between the conductive metal probes 3 of each group of the segmented pipeline; the micro resistance measuring instrument 1 and the round-robin controller 2 are respectively connected with a resistance record analysis data server 4 through a field network communication device 5, resistance values of all sections of pipelines measured at certain intervals in a round-robin mode are stored and calculated in the resistance record analysis data server 4 in real time, and are converted into scale thickness proportion values of the inner walls of the segmented pipelines through trend model calculation; and the monitoring result of the scaling trend on the inner wall of the pipeline is displayed and alarmed to a supervisory personnel and an information center through the display and alarm interface software.
The principle of the invention is that the industrial pipeline is formed by connecting sectional pipelines, when each sectional pipeline works, the inside of each sectional pipeline is filled with fluid, the inner wall of each sectional pipeline has more or less scale, the comprehensive substance of each sectional pipeline mainly comprises three substances of metal pipeline, scale and fluid, and the comprehensive resistance of each sectional pipeline is the superposition resistance of the three substances of metal pipeline, scale layer and fluid. Among the three substances, the metal pipeline is made of conductive metal components such as steel, copper, aluminum alloy and the like, and has lower resistivity, which is generally in the order of magnitude of 10 < -6 > to 10 < -8 > omega.m; the fluid has certain acid-base salt components, and the resistivity is lower, and is generally in the order of 10 < -4 > to 10 < -5 > omega.m; the scale layer is mainly silicon oxide, and has high resistivity of 10 < -1 > to 102 omega m, which is tens, hundreds or thousands times of the resistivity of metal pipelines and fluid. Actual tests prove that the change of the comprehensive resistance of each section of pipeline is mainly caused by the thickness change of the scaling layer, and the comprehensive resistance of the pipeline has a relatively obvious linear relation with the thickness of the structural layer. According to the linear relation, the thickness change of the structural layer can be accurately calculated through the change of the comprehensive resistance value of the pipeline.
The micro resistance measuring instrument 1 sends resistance measurement data to the resistance record analysis data server 4 through the field network communication equipment 5, the resistance record analysis data server 4 analyzes the data through the trend model operation display and alarm interface software 6 and generates a chart, and early warning information is sent after the resistance exceeds a set value. The resistance value record analysis data server 4 is arranged at the positions of a main control room, an information center and the like of a production factory, after the micro resistance measuring instrument 1 transmits data to the resistance value record analysis data server 4 through the field network communication equipment 5, the trend model operation display and alarm interface software 6 fits the data points into a curve along a time axis according to the accumulated scale thickness parameters of each section of metal pipe according to the period time sequence, so that the real-time change trend of the scale thickness is formed, the real-time change trend of the scale thickness can be displayed for relevant management and control personnel to watch, and meanwhile, early warning and alarm are carried out when the set alarm threshold value is exceeded.
The wheel inspection controller 2 is internally provided with a plurality of groups of wheel inspection loops, the number of the wheel inspection loops is set according to the number of metal pipe sections to be monitored, the time sequence conduction control of the wheel inspection loops is controlled by adopting PLC (programmable logic controller) and DCS (distributed control system) automatic control equipment or by a singlechip electronic circuit board, and each wheel inspection loop independently corresponds to one section of pipeline in the control system. The micro resistance measuring instrument 1 can measure the resistance value of the metal pipes one by one through the round controller 2, so that the resistance value data of each section of pipeline is obtained, and a chart is drawn conveniently.
One end of the measuring loop wire 7 passes through the metal pipe flanges, and a protective layer is arranged on the outer side of the measuring loop wire 7. The measuring loop lead 7 is soft and slim, can pass through small gaps such as connecting flange gaps, can use high-temperature resistant, corrosion resistant and other sheaths or protective layers, and can only monitor the inner tube without being influenced by the shielding of the outer tube in some working conditions with inner and outer sleeve structures.
The trend model operation display and alarm interface software 6 comprises a computer HMI interface, a mobile phone APP or applet, an analysis model database and a data transmission communication module, wherein the trend model operation display and alarm interface software 6 is used for customizing and developing various display models and alarm measures according to different users and process requirements, and developing functions of user login, authorized control and history record inquiry. The trend model operation display and alarm interface software 6 linearly converts the resistance value of each section of pipeline into the structure thickness according to the data information fed back by the micro resistance measuring instrument 1, generates a change trend curve, can be displayed for relevant management and control personnel to watch, and simultaneously performs early warning and alarm when the set alarm threshold value is exceeded.
A method for on-line monitoring the scaling and blocking trend of the inner wall of a metal pipe comprises the following steps:
step S1, an inner probe is installed at the flange connection part of each section of metal pipe, an outer probe is installed on the outer wall of each section of metal pipe, the segmented pipeline conductive metal probe 3 is connected with the wheel inspection controller 2 through a measuring loop lead 7, and the wheel inspection controller 2 is connected with the micro resistance measuring instrument 1 so that the micro resistance measuring instrument 1 is communicated with the segmented pipeline conductive metal probe 3.
In step S2, the micro resistance measuring instrument 1 measures resistance values of the round trip by the internal controller of the round trip controller 2, sends measurement data to the resistance value record analysis data server 4 through the on-site network communication device 5, measures resistance values of each section of metal tube by the micro resistance measuring instrument 1, and transmits data to the resistance value record analysis data server 4 and analyzes the data through the on-site network communication device 5.
And S3, analyzing the resistance value data in the resistance value record analysis data server 4 through the trend model operation display and alarm interface software 6 to generate a chart, displaying the chart for relevant management and control personnel to watch, and sending out early warning information when the resistance value exceeds a set value.
In the step S3, each section of metal pipe is fitted into a curve along a time axis according to the scale thickness parameter accumulated in the periodic time sequence, so as to form a scale thickness real-time variation trend, so that a worker can quantify the scale situation, and is convenient to judge whether to clean the pipeline and distinguish the scale situations of different pipelines.
The trend model operation display and alarm interface software 6 is used for customizing and developing various display models and alarm measures according to different users and process requirements, developing functions of user login, authorized control and history record inquiry, and facilitating different users to use and view structural data of pipelines.

Claims (8)

1. The utility model provides a device of on-line monitoring metal tube inner wall scale deposit jam trend which characterized in that: the measuring device comprises a micro-resistance measuring instrument (1), a round inspection controller (2), a segmented pipeline conductive metal probe (3) and a measuring loop wire (7), wherein the segmented pipeline conductive metal probe (3) comprises an outer probe and an inner probe, one end of the inner probe is inserted into the center of a metal pipe through a metal pipe flange gap, the inner probe is in good contact with fluid in the pipe, a sealing gasket is arranged between the metal pipe flanges, the inner probe is in sealing installation through the sealing gasket, the inner probe is insulated from the metal pipe, and the outer probe is welded or in good conductive connection with the outer wall of the metal pipe; the micro-resistance measuring instrument (1) is electrically connected with the wheel inspection controller (2), and the wheel inspection controller (2) is electrically connected with the segmented pipeline conductive metal probe (3) through a measuring loop wire (7).
2. The device for on-line monitoring of the scaling and plugging tendency of the inner wall of a metal pipe according to claim 1, wherein: the resistance value recording analysis data server (4), the field network communication equipment (5) and the trend model operation display and alarm interface software (6) are further included, the micro resistance measuring instrument (1) sends resistance measurement data to the resistance value recording analysis data server (4) through the field network communication equipment (5), the resistance value recording analysis data server (4) analyzes the data through the trend model operation display and alarm interface software (6) and generates a chart, and early warning information is sent out after the resistance value exceeds a set value.
3. The device for on-line monitoring of the scaling and plugging tendency of the inner wall of a metal pipe according to claim 1, wherein: the automatic monitoring device is characterized in that a plurality of groups of wheel inspection loops are arranged in the wheel inspection controller (2), the number of the wheel inspection loops is set according to the number of metal pipe sections to be monitored, the time sequence conduction control of the wheel inspection loops is controlled by adopting PLC (programmable logic controller) and DCS (distributed control system) automatic control equipment or by a singlechip electronic circuit board, and each wheel inspection loop corresponds to a section of pipeline independently in a control system.
4. The device for on-line monitoring of the scaling and plugging tendency of the inner wall of a metal pipe according to claim 1, wherein: one end of the measuring loop wire (7) passes through the metal pipe flanges, and a protective layer is arranged on the outer side of the measuring loop wire (7).
5. The device for on-line monitoring of the scaling and plugging trend of the inner wall of a metal pipe according to claim 2, wherein: the trend model operation display and alarm interface software (6) comprises a computer HMI interface, a mobile phone APP or applet, an analysis model database and a data transmission communication module, wherein the trend model operation display and alarm interface software (6) is used for customizing and developing various display models and alarm measures according to different users and process requirements and developing functions of user login, authorized control and history record inquiry.
6. A method for on-line monitoring the scaling and blocking trend of the inner wall of a metal pipe is characterized by comprising the following steps: the method comprises the following steps:
step S1, installing an inner probe at the flange joint of each section of metal pipe, installing an outer probe on the outer wall of the metal pipe, connecting the segmented pipeline conductive metal probe (3) with a wheel inspection controller (2) through a measuring loop wire (7), and connecting the wheel inspection controller (2) with a micro resistance measuring instrument (1);
step S2, the micro resistance measuring instrument (1) measures resistance values of the wheel tour loops one by one through an internal controller of the wheel tour controller (2), and sends measured data to a resistance value record analysis data server (4) through the field network communication equipment (5);
and S3, analyzing the resistance value data in the resistance value record analysis data server (4) through a trend model operation display and alarm interface software (6) to generate a chart, and sending out early warning information when the resistance value exceeds a set value.
7. The method for on-line monitoring of the scaling and plugging tendency of the inner wall of a metal pipe according to claim 6, wherein: in the step S3, each section of metal pipe is fitted into a curve along a time axis according to the accumulated scale thickness parameters of the periodic time sequence, so as to form the real-time variation trend of the scale thickness.
8. The method for on-line monitoring of the scaling and plugging tendency of the inner wall of a metal pipe according to claim 6, wherein: the trend model operation display and alarm interface software (6) is used for customizing and developing various display models and alarm measures according to different users and process requirements, and developing functions of user login, authorized control and historical record inquiry.
CN202310393941.5A 2023-04-13 2023-04-13 Device and method for on-line monitoring scaling and blocking trend of inner wall of metal pipe Pending CN116379356A (en)

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CN202310393941.5A CN116379356A (en) 2023-04-13 2023-04-13 Device and method for on-line monitoring scaling and blocking trend of inner wall of metal pipe

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CN202310393941.5A CN116379356A (en) 2023-04-13 2023-04-13 Device and method for on-line monitoring scaling and blocking trend of inner wall of metal pipe

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117685508A (en) * 2023-12-12 2024-03-12 山东容和节能环保科技有限公司 Intelligent monitoring system and method for industrial circulating water treatment based on cloud platform Internet of things

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117685508A (en) * 2023-12-12 2024-03-12 山东容和节能环保科技有限公司 Intelligent monitoring system and method for industrial circulating water treatment based on cloud platform Internet of things
CN117685508B (en) * 2023-12-12 2024-06-07 山东容和节能环保科技有限公司 Intelligent monitoring system and method for industrial circulating water treatment based on cloud platform Internet of things

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