JP2020143970A - Corrosion diagnostic system - Google Patents

Abstract

To provide a corrosion diagnostic system allowing for prediction of the outer surface corrosion position and remaining life of coated equipment and piping in a plant.SOLUTION: A corrosion diagnostic system 100 diagnosing the corrosion of a metal material side at an interface between the metal material and a non-metal material, comprises a processing device 10, and a storage device 20 holding meteorological information, construction information, design information and operation information. The processing device 10 includes: a first calculation unit 11 calculating the probability of water presence on metal surface for each position from the information of the storage device 20, calculating corrosion occurrence probability on the basis of this water presence probability, and determining that the position where the corrosion occurrence probability is greater than or equal to a prescribed threshold is a corroded position; a second calculation unit 12 calculating a corrosion rate for the corroded position on the basis of a corrosion rate prediction formula and the information of the storage device 20, calculating the amount of reduction in thickness from the corrosion rate, and determining a remaining life; and a display processing unit 13 outputting, to a display device 32, maintenance inspection unnecessary information for positions other than the corroded position determined by the first calculation unit 11 and the content of maintenance inspection for the corroded position from the remaining life determined by the second calculation unit 12.SELECTED DRAWING: Figure 1

Description

The present invention relates to a corrosion diagnosis system for diagnosing corrosion on the outer surface of equipment / piping for coating material construction in an industrial plant such as a petrochemical plant.

In order to reduce energy loss and prevent foreign matter contact, the equipment and piping of industrial plants are covered with heat insulating materials and covering materials such as concrete. In recent years, with the aging of plants, corrosion of the outer surface in contact with the covering material of equipment and piping (outer surface corrosion) has been regarded as a problem. In particular, corrosion on the outer surface of pipes constructed with heat insulating material (corrosion under heat insulating material) occurs frequently, and has become a serious problem mainly in petrochemical plants. Corrosion on the outer surface of equipment and pipes for which covering materials are applied cannot be visually observed directly from the outside. Therefore, in general maintenance and inspection, the presence or absence of external surface corrosion is personally judged from the deterioration state of the covering material, the shape of equipment and piping, etc., and the covering material is peeled off at the position where it is judged that there is external corrosion. The wall thickness is inspected by visual inspection or ultrasonic inspection.

However, in the personal judgment, the position where the outer surface corrosion does not occur is often mistakenly judged as the corrosion position and the covering material is peeled off, which is inefficient and enormous maintenance and inspection cost.

JP-A-2018-25497 Japanese Unexamined Patent Publication No. 2011-53161

Patent Document 1 is a program for improving the efficiency of maintenance and inspection of external surface corrosion in equipment and piping for covering materials. This program calculates the probability that equipment and piping will become unusable from environmental information such as temperature and operating period and corrosion information from measurements, and decides from which position to prioritize maintenance and inspection. Assist. However, although this program can correct the probability of reaching the remaining life of equipment and piping, it has the disadvantage that it cannot determine when to perform maintenance and inspection.

Further, in Patent Document 2, for the cathode anticorrosion equipment of the buried pipe, an abnormality such as corrosion is predicted and diagnosed from the cathode potential, the anode potential, the rate of change of the power supply current and the acceleration, and the frequency of digging up the buried pipeline is optimized. Therefore, a system has been proposed that streamlines maintenance and inspection and reduces costs. However, although this system can be implemented in a pipe in which a sensor for detecting an electric potential or a current is installed, there is a drawback in that it cannot be implemented in a pipe in which a sensor is not installed.

An object of the present invention is to propose a corrosion diagnosis system capable of predicting the outer surface corrosion position and remaining life of equipment / piping for coating material construction by utilizing the information possessed by the plant.

In order to achieve the above object, the corrosion diagnosis system of the present invention is a corrosion diagnosis system for diagnosing corrosion on the metal material side at the interface between a metal material and a non-metal material, and the corrosion diagnosis system is a treatment device. , The processing device has a display device, and the processing device is obtained from the outside or stored in the storage device of the own system, based on the information of weather information, design information, construction information, and operation information, for each position of the diagnostic object. The first calculation unit that calculates the water existence probability of the metal surface, calculates the corrosion occurrence probability based on the water existence probability, and determines the position of the corrosion occurrence probability as the corrosion position when the corrosion occurrence probability is equal to or more than a predetermined threshold. With respect to the determined corrosion position, the corrosion rate is calculated based on the corrosion rate prediction formula and the information in the storage device, the wall loss amount is calculated from the corrosion rate, and the remaining life is calculated based on the wall loss amount. Except for the 2 calculation unit and the corrosion position that was not determined to be the corrosion position by the 1st calculation unit, the maintenance and inspection unnecessary information is provided, and the corrosion position is the maintenance and inspection content based on the result of the remaining life calculated by the 2nd calculation unit. It is characterized by having a display processing unit that outputs to a display device. Other aspects of the present invention will be described in embodiments described below.

According to the present invention, it is possible to predict the outer surface corrosion position and the remaining life of the equipment / piping for covering material construction by utilizing the information possessed by the plant.

It is a block diagram which shows the corrosion diagnosis system which concerns on Embodiment 1. This is the content held in the storage device for the adaptive piping of the corrosion diagnosis system according to the first embodiment. It is a flowchart which shows the process of the corrosion diagnosis system which concerns on Embodiment 1. It is a water existence probability risk determination table of the adaptive pipe outer surface of the corrosion diagnosis system in the 1st calculation part which concerns on Embodiment 1. It is a calculation figure of the correction coefficient in the corrosion rate prediction formula of the 2nd calculation part which concerns on Embodiment 1. FIG. It is a figure which calculates the post-correction corrosion rate from the pre-correction corrosion rate by the correction coefficient in the corrosion rate prediction formula of the 2nd calculation part which concerns on Embodiment 1. FIG. This is an example of scheduled output for maintenance and inspection in the display device according to the first embodiment. It is a block diagram which shows the corrosion diagnosis system which concerns on Embodiment 2. It is a flowchart which shows the process of the corrosion diagnosis system which concerns on Embodiment 2. This is an example of scheduled output for maintenance and inspection in the display device according to the second embodiment. It is a block diagram of the corrosion diagnosis system which concerns on Embodiment 3. It is a flowchart which shows the process of the corrosion diagnosis system which concerns on Embodiment 3. This is the result of re-verifying the presence or absence of corrosion in the corrosion position inspection unit according to the third embodiment. It is a block diagram of the corrosion diagnosis system which concerns on Embodiment 4. It is a flowchart which shows the process of the corrosion diagnosis system which concerns on Embodiment 4. This is the result of evaluating the amount of wall loss in the remaining life correction unit according to the fourth embodiment and correcting the remaining life. It is a flowchart which shows the modification 1 of the process of the corrosion diagnosis system which concerns on Embodiment 3. It is a flowchart which shows the modification 2 of the process of the corrosion diagnosis system which concerns on Embodiment 3. It is a flowchart which shows the modification 3 of the process of the corrosion diagnosis system which concerns on Embodiment 3. It is a flowchart which shows the modification 1 of the process of the corrosion diagnosis system which concerns on Embodiment 4. It is a flowchart which shows the modification 2 of the process of the corrosion diagnosis system which concerns on Embodiment 4. It is a flowchart which shows the modification 3 of the process of the corrosion diagnosis system which concerns on Embodiment 4.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
<< Embodiment 1 >>
The corrosion diagnosis system of the present invention includes weather information (rainfall, humidity, etc.), design information (indoor / outdoor, equipment / piping shape, etc.), construction information (wrapping method of covering material), and operation information (operation) possessed by the plant. By predicting the corrosion position and remaining life of equipment and piping by utilizing temperature, years of operation, etc.), we support the determination of the position and timing for maintenance and inspection. As a result, personal judgment is reduced, and maintenance and inspection efficiency is improved and costs are reduced.

FIG. 1 is a configuration diagram showing a corrosion diagnosis system 100 according to the first embodiment. The corrosion diagnosis system 100 includes a processing device 10, a storage device 20, an input device 31, a display device 32, and a communication device 33. The treatment device 10 has water on the metal surface for each position of the object to be diagnosed based on the weather information, design information, construction information, and operation information information acquired from the outside or stored in the storage device 20 of the own system. The probability is calculated, the corrosion occurrence probability is calculated based on the water existence probability, and when the corrosion occurrence probability is equal to or higher than a predetermined threshold value, the position of the corrosion occurrence probability is determined to be the corrosion position. Regarding the corrosion position, the corrosion rate is calculated based on the corrosion rate prediction formula and the information of the storage device 20, the wall loss amount is calculated from the corrosion rate, and the remaining life is calculated based on the wall loss amount. And, except for the corroded position that was not determined to be the corroded position by the first calculation unit 11, the maintenance and inspection unnecessary information is displayed, and the corrosion position is the maintenance and inspection content based on the result of the remaining life calculated by the second calculation unit. It is configured to include a display processing unit 13 that outputs to 32.

The storage device 20 contains weather information 21 (for example, rainfall, humidity, etc.), design information 22 (for example, indoor / outdoor, equipment / piping shape, etc.), and construction information 23 (for example, how to wind a covering material) held by the plant. ), Operation information 24 (for example, operating temperature, operating years, etc.) and the like are stored. Various information held by the plant is acquired from the plant by an acquisition unit (not shown) of the processing device 10 via the network NW and the communication device 33, and stored in the storage device 20.

In the corrosion diagnosis system 100, the first calculation unit 11 calculates the water existence probability of the outer surface of the metal for each position of the equipment / piping for covering material construction that requires maintenance and inspection from the information of the storage device 20, and the water existence probability thereof. The corrosion occurrence probability is calculated based on the above, and the position of the corrosion occurrence probability when the predetermined threshold value or more is determined as the corrosion position. The second calculation unit 12 calculates the corrosion rate of the corrosion position based on the corrosion rate prediction formula and the information of the storage device 20, calculates the wall thinning amount from the corrosion rate, and determines the remaining life. The display processing unit 13 displays on the display device 32 the maintenance / inspection unnecessary information for the first calculation unit 11 other than the corrosion position, and the maintenance / inspection content for the corrosion position based on the remaining life result of the second calculation unit 12.

FIG. 2 shows the contents possessed by the storage device 20 for the adaptive piping of the corrosion diagnosis system 100 according to the first embodiment. In the present embodiment, the objects of the corrosion diagnosis system 100 are the heat insulating pipe A, the heat insulating pipe B, the heat insulating pipe C, the heat insulating pipe D, and the heat insulating pipe E on which the heat insulating material and the exterior plate are installed. Further, the plant to which the corrosion diagnosis system 100 is applied is a plant that has the following information in the storage device 20. Meteorological information 21 includes average precipitation and berthing distance, design information 22 includes equipment / piping material, equipment / piping position indoors or outdoors, heat insulating material density, and construction information 23 includes construction quality and operation of exterior plate joints. Information 24 includes years of operation and operating temperature. The heat-retaining pipe A, the heat-retaining pipe B, the heat-retaining pipe C, the heat-retaining pipe D, and the heat-retaining pipe E are stored in the stored information. FIG. 2 shows list information 25 for each adaptive pipe of the corrosion diagnosis system 100.

FIG. 3 is a flowchart showing the processing of the corrosion diagnosis system 100 according to the first embodiment. Refer to FIGS. 1 and 2 as appropriate. The processing device 10 acquires weather information 21, design information 22, construction information 23, and operation information 24 from the storage device 20 (step S11).

The first calculation unit 11 determines whether or not the probability of water presence on the metal surface is equal to or greater than a predetermined threshold value (step S12). When the threshold value is equal to or higher than the predetermined threshold value (step S12, YES), the first calculation unit 11 proceeds to step S13, and when the threshold value is lower than the predetermined threshold value (step S12, NO), the first calculation unit 11 proceeds to step S16.

In the storage device 20, when the water supply form is supplied from the outside, the amount of precipitation and the position of the equipment / piping are indoors or outdoors, and when the water supply form is dew condensation, the operating temperature is used. is there. In addition, what is related to water diffusion is the density of the heat insulating material and the quality of the construction of the exterior plate joint. Based on the risk assessment, the probability of water presence (= corrosion occurrence rate) on the outer surface of the pipe was evaluated on a 4-point scale (maximum, large, medium, small).

FIG. 4 is a water existence probability risk determination table 26 on the outer surface of the adaptive pipe of the corrosion diagnosis system 100 in the first calculation unit 11 according to the first embodiment. The threshold value for determining the corrosion position depends on the degree of influence of the accident when the equipment / piping causes a leakage accident or the like. In the present embodiment, the threshold value is set to the middle level corresponding to the second from the bottom of the four-stage evaluation, and the first calculation unit 11 sets the position when the corrosion occurrence rate is equal to or higher than the predetermined threshold value to the corrosion position and less than the threshold value. The position was judged to be other than the corrosion position. As a result, it was determined that the heat insulating pipe A, the heat insulating pipe B, and the heat insulating pipe C were in the corroded position, and the heat insulating pipe D and the heat insulating pipe E were not in the corroded position.

Returning to FIG. 3, next, the second calculation unit 12 estimates the remaining life of the heat retention pipe A, the heat retention pipe B, and the heat retention pipe C determined by the first calculation unit 11 to be in the corroded position. The second calculation unit 12 calculates the corrosion rate (step S13), calculates the wall thinning amount (step S14), and calculates the remaining life (step S15). Details will be described later. Among the information stored in the storage device 20, the parameters related to the electrochemical reaction rate are the number of years elapsed, the operating temperature, the amount of salt depending on the offshore distance, and the material of the equipment / piping.

FIG. 5 is a calculation diagram of a correction coefficient in the corrosion rate prediction formula of the second calculation unit 12 according to the first embodiment. FIG. 5 shows the relationship between the parameters and the corrosion rate calculated from literature information, actual machine wall thinning information, or element tests. In the corrosion rate prediction formula in step S13, the corrosion rate with respect to the elapsed years is the pre-correction corrosion rate. Further, the operating temperature, the amount of salt, and the material of the equipment / piping shall be the correction coefficient standardized so that the condition where the corrosion rate is the minimum value is 1. The corrosion rate prediction formula is expressed by the following formula, which is the product of the corrosion rate before correction and the correction coefficient.

Here, M (t) is the post-correction corrosion rate, m (t) is the pre-correction corrosion rate, f _T is the operating temperature correction coefficient, f _salt is the salt amount correction coefficient, and f _material is the material correction coefficient for equipment and piping. is there. FIG. 6 shows an image in which the corrosion rate before correction is corrected by each correction coefficient and the corrosion rate after correction is calculated. The corrosion rate of the heat-retaining pipe A, the heat-retaining pipe B, and the heat-retaining pipe C is calculated by inputting information on the number of years of operation, the operating temperature, the amount of salt, and the equipment / piping material into the corrosion rate prediction formula of [Equation 1].

The amount of wall thinning in step S14 is calculated by the following formula.

Regarding the calculation of the remaining life in step S15, first, the number of years T satisfying the following equation is obtained.

ここで、αは各機器・配管に設定された安全率である。 Then, the remaining life is calculated from the following equation.

Here, α is the safety factor set for each device / piping.

Returning to FIG. 3, finally, the display processing unit 13 creates a maintenance / inspection schedule using the corrosion position determined by the first calculation unit 11 and the remaining life calculated by the second calculation unit 12.

FIG. 7 is an example of a maintenance / inspection scheduled output in the display device 32 according to the first embodiment. FIG. 7 shows the maintenance and inspection schedule of the heat insulating pipe A, the heat insulating pipe B, the heat insulating pipe C, the heat insulating pipe D, and the heat insulating pipe E targeted in the present embodiment. In the row, the equipment / piping position 71, the presence / absence of corrosion 72, the amount of wall loss 73, the remaining life 74, and the next maintenance / inspection schedule 75 are described. In addition, as a line, write the name of the equipment / piping position, whether it is the corroded position calculated earlier or other than the corroded position, the amount of wall loss and the remaining life, and the next maintenance and inspection schedule. Since the remaining life is not calculated at times other than the corrosion position, the design life set at the time of delivery of equipment and piping is described. In addition, since the judgment of the corroded position and the remaining life is updated by using the latest data of the position where the wall thickness inspection was performed for each maintenance and inspection, it is necessary to describe the date of preparation in this maintenance and inspection schedule.

In this way, the corrosion diagnosis system 100 creates a maintenance / inspection schedule and clarifies the position and timing for maintenance / inspection, which contributes to high efficiency and low cost.

In the corrosion diagnosis system 100 of the present embodiment, the outer surface is thinned by the corrosion generation process until water exists on the outer surface of the equipment / pipe due to external supply of rainwater or the like or dew condensation, and the electrochemical reaction using water as a reaction field. We propose a corrosion diagnosis system that is separated into the process of corrosion progress.

The influence parameters of the corrosion occurrence process are meteorological conditions such as precipitation and humidity related to water supply, and the degree of deterioration of the covering material related to water diffusion and construction defects. It is difficult to build a model based on the theory of physicochemistry because the above parameters involve environmental disturbances and human factors. Therefore, in the corrosion generation process, the corrosion position is specified by statistical processing utilizing the above parameters or risk determination. On the other hand, the influence parameters of the corrosion progress process are the temperature and the amount of salt related to the electrochemical reaction rate. Since these parameters correlate with electrochemical reactions, a corrosion rate prediction formula based on physicochemical theory is constructed to estimate the remaining life.

The corrosion diagnosis system 100 of the present embodiment targets the outer surface of the covering material construction equipment / piping that requires maintenance and inspection of the plant, and the operation information, design information, construction information, and weather information of the equipment / piping owned by the plant. The water presence probability on the outer surface of the equipment / pipe is calculated from the storage device 20 that has accumulated the water and the influence parameters related to water supply and water diffusion in the information of the storage device 20, and the position where the water presence probability is equal to or higher than a predetermined threshold value. Is the corrosion position, and the position determined to be the corrosion position by the first calculation unit 11 and the position determined to be the corrosion position by the first calculation unit 11 are the positions determined to be other than the corrosion position, and the corrosion electricity in the storage device 20. The corrosion rate is calculated from the parameters related to the chemical reaction rate and the corrosion rate prediction formula that weights the influence of these parameters on the electrochemical reaction rate, and the amount of wall loss is calculated from the corrosion rate to estimate the remaining life. The positions other than the corrosion positions specified by the second calculation unit 12 and the first calculation unit 11 are information that does not require maintenance and inspection, and the corrosion positions specified by the first calculation unit 11 are the next time from the estimation result of the remaining life of the second calculation unit 12. It is configured to include a display processing unit 13 that outputs the maintenance and inspection time of the above to the display device 32.

In the information of the storage device 20, the influence parameters related to water supply are, for example, precipitation, humidity, whether the equipment / piping is indoors or outdoors, etc., and the influence parameters related to water diffusion are, for example, the presence / absence of a gap in the exterior plate, the type of heat insulating material. , Heat insulating material density, presence or absence of paint, etc. The first calculation unit 11 calculates the probability of water presence on the outer surface of the equipment / piping by risk determination by scoring these influence parameters or statistical analysis related to the relationship between the past corrosion occurrence and the influence parameters. Since corrosion occurs in the presence of water, the probability of water existence is synonymous with the probability of corrosion. The corrosion occurrence rate threshold is determined based on the safety standards of each device / piping, and the corrosion position is specified by setting the position above the threshold as the corrosion position and the position below the threshold as other than the corrosion position.

In the storage device 20, the influential parameters related to the electrochemical reaction rate are, for example, the operating temperature, the amount of salt, the material of equipment / piping, and the number of years of operation. The relationship between these influence parameters and the corrosion rate is calculated in advance from literature information, actual machine thinning inspection information, or element tests. The corrosion rate prediction formula of the second calculation unit 12 is constructed by the product of the influence parameters. Enter the value of the effect parameter of the storage device into the corrosion rate prediction formula to calculate the corrosion rate.

The second calculation unit 12 calculates the amount of wall loss as an integral value of the corrosion rate with respect to the elapsed years. Further, the second calculation unit 12 estimates the remaining life by using the wall thickness, the amount of wall reduction, the minimum required wall thickness, and the corrosion rate.

In the display processing unit 13, maintenance / inspection unnecessary information is provided to the outer surface of the covering material construction equipment / piping that requires maintenance and inspection of the plant at positions other than the corrosion position determined by the first calculation unit 11. As for the corrosion position estimated by the remaining life in 12, the remaining life is displayed on the display device 32. Furthermore, by outputting the recommended date and time for maintenance and inspection from the next time onward, the position and timing of maintenance and inspection can be planned.

<< Embodiment 2 >>
FIG. 8 is a configuration diagram showing a corrosion diagnosis system 100A according to the second embodiment. The second embodiment is different from the configuration of the first embodiment in that the processing device 10 has a wall thinning information utilization unit 18. In FIG. 8, the same components shown in FIG. 1 are designated by the same reference numerals, and the description thereof will be omitted.

The processing device 10 of the corrosion diagnosis system 100A determines whether the corrosion position is a corrosion position or a non-corrosion position based on the first calculation unit 11, the second calculation unit 12, the display processing unit 13, and the previous wall thinning inspection result. The information utilization unit 18 is included. The thinning information 27 is stored in the storage device 20. Therefore, in the present embodiment, in the plant, the position where the previous wall thinning inspection data is present is targeted in the equipment / piping for covering material construction.

FIG. 9 is a flowchart showing the processing of the corrosion diagnosis system 100A according to the second embodiment. In FIG. 9, the same processing described in FIG. 3 is designated by the same reference numeral, and the description thereof will be omitted. The wall thinning information utilization unit 18 determines whether it is a corroded position or a position other than the corroded position based on the result of the previous wall thinning inspection (step S21).

When the wall thinning information utilization unit 18 determines that there is no wall thinning in the previous inspection (step S21, NO), that is, the position determined by the wall thinning information utilization unit 18 other than the corrosion position is corroded after the previous inspection. In the same manner as in the first embodiment, the first calculation unit 11 determines whether the position is a corroded position or a position other than the corroded position (step S12).

On the other hand, when the wall thinning information utilization unit 18 determines that there is wall thinning in the previous inspection (step S21, YES), that is, the position determined by the wall thinning information utilization unit 18 to be a corroded position is the second calculation unit. In step 12, the amount of wall loss is calculated (step S14A) and the remaining life is calculated (step S15). The amount of meat loss is calculated by the following formula.

The remaining life is calculated based on the above [Equation 5].

Finally, the display processing unit 13 creates a maintenance / inspection schedule for the equipment / piping using the corrosion position and the remaining life (step S16).

FIG. 10 is an example of a maintenance / inspection scheduled output in the display device 32 according to the second embodiment. The maintenance and inspection schedule of the present embodiment is the same as most of the contents shown in FIG. 7 of the first embodiment, but as an additional point, the previous wall thinning amount 77 including the previous maintenance and inspection date is added to the column and the previous thickness is reduced to 77 in the row. Add the maintenance inspection date and the result of the previous wall thinning amount.

The corrosion diagnosis system 100A of the second embodiment is a system for imparting a wall thinning information utilization unit 18 to the corrosion diagnosis system 100 of the first embodiment. This corrosion diagnosis system 100A targets the outer surface of the equipment / piping for covering material construction, which holds the previous information on the wall thinning inspection. The wall thinning information utilization unit 18 determines that the position where the wall thinning was observed last time is a corrosion position, and the second calculation unit 12 estimates the remaining life. Further, since there is a possibility that the position where the wall thinning was not observed last time has been corroded from the previous inspection to the present, the first calculation unit 11 determines the presence or absence of corrosion.

Since the information on the amount of wall loss actually measured in the previous inspection can be utilized in the second embodiment, the reliability of the corrosion position identification and the estimation of the remaining life is further improved as compared with the first embodiment.

<< Embodiment 3 >>
FIG. 11 is a configuration diagram showing a corrosion diagnosis system 100B according to the third embodiment. The third embodiment is different in that the processing apparatus 10 has a corrosion position inspection unit 30 in addition to the configuration of the first embodiment. In FIG. 11, the same components shown in FIG. 1 are designated by the same reference numerals, and the description thereof will be omitted.

The processing device 10 of the corrosion diagnosis system 100B targets the positions determined by the first calculation unit 11, the second calculation unit 12, the display processing unit 13, and the first calculation unit 11 to be other than the corrosion position, and is a corrosion sensor. It is configured to include a corrosion position inspection unit 30 that inspects whether or not the position is truly other than the corrosion position based on the information from 51 or the information from an inspection device (for example, a neutron moisture meter 52). The corrosion sensor 51 includes an ultrasonic measurement for directly measuring the wall thickness of the pipe, a DC resistance sensor for measuring the corrosion rate, and the like.

FIG. 12 is a flowchart showing the processing of the corrosion diagnosis system 100B according to the third embodiment. In FIG. 12, the same processing described in FIG. 3 is designated by the same reference numeral, and the description thereof will be omitted. If it is determined in step S12 that the position is other than the corrosion position (step S12, NO), the corrosion position inspection unit 30 determines whether or not water is detected in the heat insulating material based on information such as the neutron moisture meter 52. (Step S31). If there is water detection in the heat insulating material (steps S31, YES), the process proceeds to step S13, and if there is no water detection in the heat insulating material (steps S31, NO), the process proceeds to step S16.

In the present embodiment, the corrosion position inspection unit 30 re-verifies the corrosion position using the neutron moisture meter 52 for the three locations of the heat insulating material construction pipe determined to be other than the corrosion position by the first calculation unit 11. An example is shown. The neutron moisture meter 52 counts the numerical value of fast neutrons irradiated from a neutron source (calipornium, etc.) colliding with water in the heat insulating material and changing to slow thermal neutrons, and water in the heat insulating material. It is an inspection device that detects. The presence or absence of corrosion is indirectly predicted from the detected water. With the neutron moisture meter, the probability of water presence on the outer surface of the pipe can be predicted with high accuracy without peeling the heat insulating material.

FIG. 13 is a result of re-verifying the presence or absence of corrosion in the corrosion position inspection unit 30 according to the third embodiment. FIG. 13 shows the result of applying the neutron moisture meter 52 to a position determined by the first calculation unit 11 other than the corrosion position. Water was not detected in the heat insulating pipe YB and the heat insulating pipe YC, but water was detected in the heat insulating pipe YA. Therefore, the position where water was detected was redetermined as a corroded position because it is estimated that water exists on the outer surface of the pipe with high probability. The position determined to be the corroded position by the corrosion position inspection unit 30 is estimated by the second calculation unit 12 by the same method as in the first embodiment.

The corrosion diagnosis system 100B of the third embodiment is a system that imparts a corrosion position inspection unit 30 to the corrosion diagnosis system 100. The corrosion diagnosis system 100B targets a position determined by the first calculation unit 11 other than the corrosion position. The corrosion position inspection unit 30 evaluates the presence or absence of corrosion by an inspection device such as a neutron moisture meter 52 or an acoustic emission measuring instrument or a corrosion sensor 51 capable of evaluating the presence or absence of corrosion by non-destructive or partial destruction of the coating material, and determines the corrosion position. Reduce the risk of oversight.

This embodiment is a corrosion diagnosis system having higher safety than the first embodiment because the risk of overlooking the corroded position is reduced by re-verifying other than the corroded position by the corrosion position inspection unit 30.

<< Embodiment 4 >>
FIG. 14 is a block diagram of the corrosion diagnosis system 100C according to the fourth embodiment. The fourth embodiment is different from the configuration of the first embodiment in that the processing device 10 has a remaining life correction unit 40. In FIG. 14, the same components shown in FIG. 1 are designated by the same reference numerals, and the description thereof will be omitted.

The processing device 10 of the corrosion diagnosis system 100C targets the corrosion positions where the remaining life calculated by the first calculation unit 11, the second calculation unit 12, the display processing unit 13, and the second calculation unit 12 is equal to or less than a predetermined threshold value. It is configured to include a remaining life correction unit 40 that obtains an actually measured value of the wall thinning amount by an inspection device and corrects the remaining life.

FIG. 15 is a flowchart showing the processing of the corrosion diagnosis system 100C according to the fourth embodiment. After calculating the remaining life in step S15, the remaining life correction unit 40 determines whether or not the remaining life is equal to or less than a predetermined threshold value (step S41), and if the remaining life is equal to or less than the predetermined threshold value (steps S41, YES). ), The actual measurement value of the wall thinning amount by the inspection device is acquired, the remaining life is corrected (step S42), and the process proceeds to step S16. On the other hand, when the remaining life exceeds the threshold value (steps S41 and NO), the process proceeds to step S16.

In the present embodiment, the eddy current flaw detector 53 is located at a position where the remaining life is equal to or less than a predetermined threshold value in the remaining life correction unit 40 for three locations of the heat insulating material construction pipe whose remaining life is estimated by the second calculation unit 12. 14) is used to evaluate the amount of wall loss to correct the remaining life. The eddy current flaw detector 53 generates an eddy current in a metal by a magnetic field, detects the amount of change in the eddy current value at the wall thinning portion, and calculates the wall thinning amount from the detected change amount of the eddy current value. It is an inspection device to be used. The eddy current flaw detector 53 can measure the amount of wall thinning on the outer surface of the pipe with high accuracy without peeling the heat insulating material.

FIG. 16 is a result of evaluating the amount of wall loss in the remaining life correction unit 40 according to the fourth embodiment and correcting the remaining life. FIG. 16 shows the results of applying the eddy current flaw detector 53 to the three locations of the heat insulating material construction pipe by the second calculation unit 12. In the present embodiment, the threshold value of the remaining life is set to 5 years. Among the three locations of the heat insulating material construction pipe, the heat insulating pipe ZA had a remaining life of less than or equal to a predetermined threshold value. Therefore, the amount of wall loss of the heat insulating pipe ZA was measured by the eddy current flaw detector 53. As a result, it was 0.3 mm deeper than the wall thinning amount calculated by the second calculation unit 12. Therefore, in order to correct the remaining life, the number of years T satisfying the following equation was first obtained.

そして［数４］より、補正した余寿命を算出した。

Then, the corrected remaining life was calculated from [Equation 4].

The corrosion diagnosis system 100C of the fourth embodiment is a system that imparts a remaining life correction unit 40 to the corrosion diagnosis system 100 of the first embodiment. The corrosion diagnosis system 100C targets a position where the remaining life is equal to or less than a predetermined threshold value among the positions estimated by the second calculation unit 12 for the remaining life. In the remaining life correction unit 40, an eddy current flaw detector 53 (see FIG. 14) and an ultrasonic guided wave flaw detector, which can evaluate the amount of wall loss due to corrosion by actual measurement of the amount of wall loss, or by non-destructive or partial failure of the covering material. The remaining life is corrected by an inspection device such as a device, a radiation sensor, and an ultrasonic pig.

In the present embodiment, the remaining life correction unit 40 measures the amount of wall loss and corrects the remaining life at the corrosion position where the remaining life is equal to or less than a predetermined threshold value. As a result, the risk of an accident occurring before the next scheduled maintenance and inspection date is reduced, so that this is a corrosion diagnosis system with higher safety than that of the first embodiment.

≪Modification example≫
Although the corrosion diagnosis system 100 and the like according to the present invention have been described above in each embodiment, the present invention is not limited to these descriptions, and various modifications can be made.

The corrosion position inspection unit 30 of the third embodiment has described that it determines whether or not water is detected in the heat insulating material based on the information of the neutron moisture meter 52 (step S31), but the present invention is limited to this. Do not mean.

<Modification 1 of Embodiment 3>
The processing apparatus 10 acquires corrosion presence / absence information by an acoustic emission inspection device that detects the presence / absence of corrosion by detecting elastic waves generated from the rust layer due to corrosion at a position determined by the first calculation unit 11 other than the corrosion position. However, it may have a corrosion position inspection unit 30 that redetermines the corrosion position based on the acquired corrosion presence / absence information.

FIG. 17 is a flowchart showing a modification 1 of the process of the corrosion diagnosis system 100B according to the third embodiment. In FIG. 17, the same processing described in FIG. 12 is designated by the same reference numerals, and the description thereof will be omitted. Regarding the position determined to be other than the corrosion position in step S12 (step S12, NO), the corrosion position inspection unit 30 detects the presence or absence of corrosion by the acoustic emission inspection device that detects the elastic wave generated from the rust layer due to corrosion and determines the presence or absence of corrosion. Information is acquired and it is determined whether or not there is corrosion (step S31A). If it is determined that there is corrosion (step S31A, YES), the process proceeds to step S13, and if it is determined that there is no corrosion (step S31A, NO), the process proceeds to step S16.

The corrosion position inspection unit 30 can evaluate the presence or absence of corrosion based on the information of the inspection device of the acoustic emission measuring instrument, and reduce the risk of overlooking the corrosion position.

<Modification 2 of Embodiment 3>
The processing device 10 directly measures the amount of wall loss, changes the resistance value, and quantifies the amount of corrosion from the current value with respect to the position determined by the first calculation unit 11 other than the corrosion position (see FIG. 11). It may have a corrosion position inspection unit 30 that acquires corrosion presence / absence information from the above and redetermines the corrosion position based on the acquired corrosion presence / absence information. The corrosion sensor 51 includes an ACM (Atmospheric Corrosion Monitor) type corrosion sensor (commonly known as an ACM sensor).

FIG. 18 is a flowchart showing a modification 2 of the process of the corrosion diagnosis system 100B according to the third embodiment. In FIG. 18, the same processing described in FIG. 12 is designated by the same reference numerals, and the description thereof will be omitted. Regarding the position determined to be other than the corrosion position in step S12 (step S12, NO), the corrosion position inspection unit 30 directly measures the wall thinning amount, changes the resistance value, and quantifies the corrosion amount from the current value (FIG. 11). (Refer to), corrosion presence / absence information is acquired, and whether or not there is corrosion is determined based on the acquired corrosion presence / absence information (step S31B). If it is determined that there is corrosion (step S31B, YES), the process proceeds to step S13, and if it is determined that there is no corrosion (step S31B, NO), the process proceeds to step S16.

The corrosion position inspection unit 30 can evaluate the presence or absence of corrosion based on the information of the corrosion sensor 51 and reduce the risk of overlooking the corrosion position.

<Modification 3 of Embodiment 3>
The processing device 10 acquires corrosion presence / absence information from a radiation transmitter that detects the difference in the amount of radiation transmission between the sound portion and the thinned portion with respect to the position determined by the first calculation unit 11 other than the corrosion position. It may have a corrosion position inspection unit 30 that redetermines the corrosion position based on the corrosion presence / absence information.

FIG. 19 is a flowchart showing a modification 3 of the process of the corrosion diagnosis system 100B according to the third embodiment. In FIG. 19, the same processing described in FIG. 12 is designated by the same reference numeral, and the description thereof will be omitted. Regarding the position determined to be other than the corrosion position in step S12 (step S12, NO), the corrosion position inspection unit 30 acquires corrosion presence / absence information from the radiation transmitter that detects the difference in the amount of radiation transmission between the healthy part and the thinned part. , It is determined whether or not there is corrosion based on the acquired information on the presence or absence of corrosion (step S31C). If it is determined that there is corrosion (step S31C, YES), the process proceeds to step S13, and if it is determined that there is no corrosion (step S31C, NO), the process proceeds to step S16.

The corrosion position inspection unit 30 can evaluate the presence or absence of corrosion based on the information of the radiation transmitter and reduce the risk of overlooking the corrosion position.

<Modification 1 of Embodiment 4>
The processing device 10 is a position where the remaining life is estimated by the second calculation unit 12 and the remaining life is equal to or less than the threshold value, and the ultrasonic wave emitted from the sensor installed on the metal of the device / outer surface at that position. The wall thinning amount is acquired by an ultrasonic guided wave flaw detector that detects the guide wave, which is a type of the above, and evaluates the wall thinning amount at the position and its vicinity from the detected guide wave value, and the wall thickness at the position is thinned. It may have the remaining life correction unit 40 which evaluates the amount and corrects the remaining life from the evaluated thinning amount.

FIG. 20 is a flowchart showing a modification 1 of the process of the corrosion diagnosis system 100C according to the fourth embodiment. In FIG. 20, the same processing described in FIG. 15 is designated by the same reference numerals, and the description thereof will be omitted. After calculating the remaining life in step S15, the remaining life correction unit 40 determines whether or not the remaining life is below the threshold value (step S41), and if the remaining life is below the threshold value (steps S41, YES), ultrasonic waves. The actual measurement value of the wall thinning amount by the inspection device of the guide wave flaw detector is acquired, the remaining life is corrected (step S42A), and the process proceeds to step S16. On the other hand, when the remaining life exceeds the threshold value (steps S41 and NO), the process proceeds to step S16.

In this embodiment, the remaining life correction unit 40 measures the amount of wall loss and corrects the remaining life at the corrosion position where the remaining life is equal to or less than the threshold value in the calculation unit. As a result, the risk of an accident occurring before the next scheduled maintenance and inspection date is reduced, so that this is a corrosion diagnosis system with higher safety than that of the first embodiment.

<Modification 2 of Embodiment 4>
The processing device 10 is set with photons incident on the equipment / pipe at the position from the X-ray or gamma ray source at the position where the remaining life is equal to or less than the threshold value among the positions estimated by the second calculation unit 12. It discriminates into the energy region, detects the ratio of the number of discriminated photons, obtains the amount of wall thinning by the radiation line sensor that evaluates the amount of wall loss from the ratio of the detected number of photons, and obtains the amount of wall loss at the position. It may have the remaining life correction unit 40 which evaluates and corrects the remaining life from the evaluated wall thinning amount.

FIG. 21 is a flowchart showing a modification 2 of the process of the corrosion diagnosis system 100C according to the fourth embodiment. In FIG. 21, the same processing described in FIG. 15 is designated by the same reference numerals, and the description thereof will be omitted. After calculating the remaining life in step S15, the remaining life correction unit 40 determines whether or not the remaining life is below the threshold value (step S41), and if the remaining life is below the threshold value (steps S41, YES), the radiation line. The measured value of the wall thinning amount by the sensor is acquired, the remaining life is corrected (step S42B), and the process proceeds to step S16. On the other hand, when the remaining life exceeds the threshold value (steps S41 and NO), the process proceeds to step S16.

In the present embodiment, the remaining life correction unit 40 measures the amount of wall loss and corrects the remaining life at the corrosion position where the remaining life is equal to or less than the threshold value. As a result, the risk of an accident occurring before the next scheduled maintenance and inspection date is reduced, so that this is a corrosion diagnosis system with higher safety than that of the first embodiment.

<Modification 3 of Embodiment 4>
The processing device 10 targets a pipe in a position where the remaining life is equal to or less than a threshold value among the positions estimated by the second calculation unit 12, and the wall thinning depth inside and outside the pipe is reduced by at least one of ultrasonic waves and leakage magnetic flux. It has a remaining life correction unit 40 that acquires the measured value of the wall thinning amount by the ultrasonic inspection pig that measures the thickness, evaluates the wall thinning amount at the position, and corrects the remaining life from the evaluated wall thinning amount. May be.

FIG. 22 is a flowchart showing a modification 3 of the process of the corrosion diagnosis system 100C according to the fourth embodiment. In FIG. 22, the same processing described in FIG. 15 is designated by the same reference numerals, and the description thereof will be omitted. After calculating the remaining life in step S15, the remaining life correction unit 40 determines whether or not the remaining life is below the threshold value (step S41), and if the remaining life is below the threshold value (steps S41, YES), ultrasonic waves. The measured value of the wall thinning amount by the inspection pig is acquired, the remaining life is corrected (step S42C), and the process proceeds to step S16. On the other hand, when the remaining life exceeds the threshold value (steps S41 and NO), the process proceeds to step S16.

In the present embodiment, the remaining life correction unit 40 measures the amount of wall loss and corrects the remaining life at the corrosion position where the remaining life is equal to or less than the threshold value. As a result, the risk of an accident occurring before the next scheduled maintenance and inspection date is reduced, so that this is a corrosion diagnosis system with higher safety than that of the first embodiment.

According to this corrosion diagnosis system, in the plant, the probability of water presence and the corrosion rate on the outer surface that requires maintenance and inspection of the equipment and piping for coating material construction are evaluated, and the corrosion position of the equipment and piping and the estimated remaining life are calculated. can do. As a result, it is possible to improve the efficiency and cost of maintenance and inspection by planning the position and timing for maintenance and inspection of equipment and piping.

10 Processing device 11 1st calculation unit 12 2nd calculation unit 13 Display processing unit 18 Wall thinning information utilization unit 20 Storage device 21 Meteorological information 22 Design information 23 Construction information 24 Operation information 25 List information 26 Water existence probability risk judgment table 27 Reduction Meat information 30 Corrosion position inspection unit 31 Input device 32 Display device 33 Communication device 40 Remaining life correction unit 51 Corrosion sensor 52 Neutron moisture meter 53 Vortex current flaw detector 100, 100A, 100B, 100C Corrosion diagnosis system

Claims (14)

A corrosion diagnosis system for diagnosing corrosion on the metallic material side at the interface between a metallic material and a non-metallic material.
The corrosion diagnosis system has a processing device and a display device.
The processing device is
The probability of water presence on the metal surface is calculated for each position of the object to be diagnosed based on the weather information, design information, construction information, and operation information that are acquired from the outside or stored in the storage device of the own system. A first calculation unit that calculates the corrosion occurrence probability based on the water existence probability and determines the position of the corrosion occurrence probability as the corrosion position when the corrosion occurrence probability is equal to or higher than a predetermined threshold.
For the determined corrosion position, the corrosion rate is calculated based on the corrosion rate prediction formula and the information of the storage device, the wall loss amount is calculated from the corrosion rate, and the remaining life is calculated based on the wall loss amount. 2nd calculation unit and
Other than the corrosion position that was not determined to be the corrosion position by the first calculation unit, maintenance and inspection unnecessary information is provided, and the corrosion position is the maintenance and inspection content based on the result of the remaining life calculated by the second calculation unit. A corrosion diagnosis system characterized by having a display processing unit that outputs to a display device. In claim 1,
The first calculation unit performs risk determination by scoring the parameters for parameters related to water supply and water diffusion in the information, or statistical analysis related to the relationship between past corrosion occurrence and the parameters for each position. The water existence probability of the metal surface is calculated, the corrosion occurrence probability is calculated based on the water existence probability, and when the corrosion occurrence probability is equal to or more than a predetermined threshold value, the position of the corrosion occurrence probability is set as the corrosion position, and the corrosion occurrence probability is calculated. A corrosion diagnostic system characterized in that if it is less than a predetermined threshold, it is not in the corrosion position. In claim 1,
Regarding the corrosion rate prediction formula, the second calculation unit calculates the relationship between the parameter related to the electrochemical reaction rate of corrosion and the corrosion rate from element tests, literature information, or actual machine wall thinning inspection information, and from the product of the parameters. A corrosion diagnostic system characterized by constructing a corrosion rate prediction formula. In claim 1,
The display processing unit provides unnecessary information for maintenance and inspection at positions determined by the first calculation unit other than the corrosion position with respect to the positions of equipment and piping for covering material construction that require maintenance and inspection of the plant. For the corrosion position estimated by the calculation unit, the remaining life is displayed on the display device, and the position and timing of maintenance and inspection are planned and output to the display device with respect to the position of the equipment / piping for the construction of the covering material. Corrosion diagnostic system characterized by In claim 1,
The processing device also has a wall thinning information utilization unit that determines the corrosion position based on the wall thinning inspection information, targeting the positions of the equipment / piping of the covering material construction that owns the wall thinning inspection information up to the previous time. And
The meat reduction information utilization department
For the position determined to be other than the corrosion position by the previous inspection, the probability of corrosion occurrence after the previous inspection is calculated by the first calculation unit, and the presence or absence of corrosion is determined.
A corrosion diagnosis system characterized in that the second calculation unit estimates the remaining life of a position determined to be a corroded position by determining that there is wall thinning in the previous inspection. In claim 1 or 5,
The processing device acquires the amount of water in the heat insulating material from the neutron moisture meter at a position determined by the first calculation unit other than the corrosion position, and based on the acquired amount of water, the metal surface of each position. A corrosion diagnosis system characterized by having a corrosion position inspection unit that corrects the water existence probability and redetermines the corrosion position. In claim 1 or 5,
The processing device acquires corrosion presence / absence information from an acoustic emission inspection device that detects the presence / absence of corrosion by detecting an elastic wave generated from the rust layer due to corrosion at a position determined by the first calculation unit other than the corrosion position. A corrosion diagnosis system characterized by having a corrosion position inspection unit that redetermines whether or not the position is corroded based on the acquired information on the presence or absence of corrosion. In claim 1 or 5,
The processing apparatus acquires corrosion presence / absence information from a corrosion sensor that quantifies the amount of corrosion at a position determined by the first calculation unit other than the corrosion position, and whether or not it is a corrosion position based on the acquired corrosion presence / absence information. A corrosion diagnosis system characterized by having a corrosion position inspection unit for re-determining. In claim 1 or 5,
The processing device detects the difference in the amount of radiation transmission between the healthy part and the thinned part with respect to the position determined by the first calculation unit other than the corrosion position, and determines the presence or absence of corrosion from the difference in the detected radiation transmission amount. A corrosion diagnosis system characterized by having a corrosion position inspection unit that acquires corrosion presence / absence information from a radiation penetrator for determination and re-determines whether or not it is a corrosion position based on the acquired corrosion presence / absence information. 1, claim 5, claim 6, claim 7, claim 8 or claim 9.
The processing apparatus acquires the amount of wall loss from an inspection device that measures the amount of wall loss at a position where the remaining life is equal to or less than a predetermined threshold value among the positions estimated by the second calculation unit. A corrosion diagnosis system characterized by having a remaining life correction unit that corrects the remaining life from the acquired wall thickness reduction. 1, claim 5, claim 6, claim 7, claim 8 or claim 9.
The processing device acquires the amount of wall loss from an eddy current flaw detector that measures the amount of wall loss at a position where the remaining life is equal to or less than a predetermined threshold value among the positions estimated by the second calculation unit. , A corrosion diagnosis system characterized by having a remaining life correction unit that corrects the remaining life from the acquired wall thickness reduction amount. 1, claim 5, claim 6, claim 7, claim 8 or claim 9.
The processing device acquires the amount of wall loss from an ultrasonic guided wave flaw detector that measures the amount of wall loss at a position where the remaining life is equal to or less than a threshold value among the positions estimated by the second calculation unit. , A corrosion diagnosis system characterized by having a remaining life correction unit that corrects the remaining life from the acquired wall thickness reduction amount. Regarding claim 1, claim 5, claim 6, claim 7, claim 8 or claim 9.
In the processing device, photons incident on the equipment / pipe at the position from the X-ray or gamma ray source are set with respect to the position where the remaining life is equal to or less than the threshold value among the positions estimated by the second calculation unit. It discriminates into the energy region, detects the ratio of the number of discriminated photons, acquires the amount of wall loss from the radiation sensor that measures the amount of wall loss from the ratio of the detected number of photons, and obtains the amount of wall loss from the acquired amount of wall loss. A corrosion diagnosis system characterized by having a remaining life correction unit that corrects the remaining life. 1, claim 5, claim 6, claim 7, claim 8 or claim 9.
The processing device targets a pipe in a position where the remaining life is equal to or less than a predetermined threshold value among the positions estimated by the second calculation unit, and the amount of wall loss is measured from an ultrasonic inspection pig that measures the amount of wall loss. A corrosion diagnosis system characterized by having a remaining life correction unit for correcting the remaining life from the acquired wall thickness reduction amount.

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