WO2020207076A1

WO2020207076A1 - Explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning on-line detection system and method

Info

Publication number: WO2020207076A1
Application number: PCT/CN2020/070211
Authority: WO
Inventors: 赵扬; 郭锐; 宋江峰; 刘帅; 马健; 陈建伟; 南钢洋; 白雪
Original assignee: 山东省科学院激光研究所
Priority date: 2019-04-09
Filing date: 2020-01-03
Publication date: 2020-10-15
Also published as: CN109973828A

Abstract

An explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning on-line detection system and method, which use an explosion-proof electromagnetic ultrasonic detection system consisting of an explosion-proof tank (1), a high-speed data acquisition module, an excitation module, an infinite transmission module (3), and an explosion-proof electromagnetic ultrasonic transducer (8). Ultrasonic transverse waves are excited in a pipeline to be detected by utilizing the system, and the transverse waves propagate along the thickness direction of the pipeline. Ultrasonic waves reflected by the inner wall of the pipeline are received in a self-transmitting and self-receiving manner, and the thickness of the pipeline is calculated according to time duration of the ultrasonic waves propagating in the pipeline and the calibrated wave velocity. Thickness data of the pipeline is transmitted to a server in real time in a wireless transmission manner, and online detection of corrosion thinning of the pipeline in an explosive environment is achieved.

Description

Flameproof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system and method

Technical field

The invention belongs to the field of electromagnetic ultrasonic detection, and particularly relates to an explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system and method.

Background technique

Oil and natural gas are the main energy sources indispensable for the development of the national economy and people’s lives. Oil and gas storage and transportation facilities are responsible for the important mission of ensuring the production and supply of oil and gas energy. At present, 70% of oil and 90% of natural gas in my country are transported through pipelines. During the long-term service of the pipelines in the petrochemical park, cracks, corrosion and weld undercuts in the pipelines due to chemical, physical or electrochemical effects are very common, which makes the pipeline thinner and the pressure-bearing capacity decreases. In severe cases, leakage, Accidents such as pipe bursts or even explosions. Since 2010, there have been many oil and gas pipeline accidents in my country, such as the "3.15" natural gas pipeline leakage in Wuhan; the "5.2" crude oil pipeline burst in Jiaozhou, Shandong; the "6.18" natural gas leakage accident in Jinzhou, Hebei; and the "7.28" propylene pipeline in Nanjing, Jiangsu Leakage and explosion accident; the "11.22" Sinopec Donghuang oil pipeline leakage and explosion accident in Qingdao, Shandong, etc., caused serious casualties, property losses and environmental pollution. Therefore, the use of advanced detection and monitoring technology and equipment to detect pipeline corrosion failure early can eliminate safety hazards in time and prevent safety accidents.

technical problem

The survey found that in my country's petrochemical industry, the corrosion problem of refining and chemical pipelines has become increasingly prominent. Corrosion detection and protection of refining and chemical oil and gas pipelines has become a common technical problem in the entire field of non-destructive testing.

According to statistics, about 41% of equipment accidents in refining and chemical production equipment are caused by corrosion. During the long-term service of petrochemical plants, metal damage or deterioration due to chemical, physical or electrochemical effects is very common. Common corrosion forms include pitting corrosion, corrosion cracking, delamination corrosion, general corrosion, and intergranular corrosion. For technical and economic reasons, corrosion of equipment and pipelines in refining and chemical production equipment is inevitable. The key is how to monitor the corrosion status in time and eliminate hidden accidents. Especially under the trend of deteriorating crude oil or changing raw material composition, how to grasp the corrosion trend and law of production equipment and pipelines in time and take anti-corrosion measures in advance is a major technical problem that petroleum refining companies need to solve urgently. Whether the production equipment can operate stably, long and optimally. At present, the domestic and foreign petrochemical industries have great demand for the detection of equipment corrosion and thinning safety issues. Due to the flammable, explosive and toxic characteristics of oil and gas, once it leaks, it is easy to cause fires, explosions, poisoning and other accidents, causing huge casualties and economic losses. Similar accidents are common at home and abroad. In addition, many facilities of my country's existing petrochemical equipment have been in service for more than 20 years. When the accident is high, it is necessary to vigorously apply and develop detection technology to provide a good guarantee for the safety of my country's petrochemical equipment.

According to the equipment anti-corrosion management experience of domestic and foreign refining and chemical enterprises, equipment and pipeline thickness measurement, especially on-line fixed-point thickness measurement, is the most commonly used and effective technical means to monitor uniform corrosion and erosion corrosion. It is similar to equipment and Monitoring method of pipeline corrosion state. The traditional on-line fixed-point thickness measurement is mainly piezoelectric ultrasonic testing technology, which requires tight coupling during testing. The method of welding and installing studs on the surface of the monitored workpiece is often used, which not only destroys the anti-corrosion structure of the equipment surface, but also affects the material of the equipment itself. It has a certain impact and requires high surface roughness of the tested surface. When used in long-term real-time online monitoring, it is easily affected by the vibration of the monitoring equipment, resulting in unstable monitoring data. Piezoelectric ultrasound is tightly coupled with the tested workpiece at the same time Therefore, it is inevitable to destroy the anti-corrosion structure of the monitored equipment surface, which increases the external corrosion risk of the equipment. Due to the large number of problems in the traditional piezoelectric ultrasonic inspection system for long-term online inspection, therefore, a lot of manpower, material and financial resources have been invested in the research and development of ultrasonic fixed-point thickness measurement equipment at home and abroad to develop ultrasonic inspection based on the principle of electromagnetic energy conversion. system.

Electromagnetic ultrasonic testing technology (English abbreviation EMAT) is a testing technology that has developed rapidly internationally in recent years. It is also one of the cutting-edge technologies in the field of ultrasonic testing. It combines electromagnetic technology and ultrasonic technology. Non-contact does not require couplant and Limited by the geometry of the tested material and surface corrosion, the equipment is simple and portable, combined with wireless acquisition and transmission technology, is becoming a popular technical method for online inspection of petrochemical equipment. The energy conversion of EAMT is carried out directly in the surface of the workpiece to be inspected. The surface of the workpiece can be regarded as a traditional piezoelectric ultrasonic probe. Therefore, the ultrasonic wave generated by EMAT does not require any coupling medium, and can be transmitted and transmitted to it without contact with the inspected workpiece. Receive, from the detection principle, there is no problem of piezoelectric ultrasonic coupling. Electromagnetic ultrasound has the characteristics of non-contact detection, high precision, high sensitivity and high speed. It is suitable for use in harsh environments such as high temperature, corrosiveness, radiation, and fast moving speed of the tested part. This technology can simultaneously excite surface waves Various wave types, such as longitudinal wave and transverse wave, can detect different types of defects at the same time. At present, the EMAT corrosion detection system on the domestic market is a portable thickness measurement system. The lift-off distance of the transducer is less than 2mm, which has high requirements on the surface of the sample, and it has not passed the explosion-proof certification of the National Electrical Explosion-proof Supervision Center and cannot be used in explosive environments. Among them, the detection object is not the metal pipeline in the flammable and explosive chemical park, and it is difficult to apply to the monitoring of the pipeline safety status. Most of the metal pipeline detection in the flammable and explosive chemical park still relies on the traditional piezoelectric ultrasonic detection technology. At present, there is a great need to develop electromagnetic and ultrasonic oil and gas pipeline thinning detection devices with electrical explosion-proof functions in the environment of chemical parks.

Technical solutions

The problem to be solved by the present invention is to overcome the shortcomings of the background technology and provide a flameproof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system and method.

The present invention is realized through the following technical solutions:

An explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system, including an electromagnetic ultrasonic transducer, a high-speed data acquisition module, an excitation module, an intrinsically safe isolation module, a wireless transmission module and a lithium battery; the high-speed data acquisition module, The excitation module, intrinsically safe isolation module and lithium battery are packaged in an explosion-proof box; the high-speed data acquisition module, excitation module and intrinsically safe isolation module are all connected to the lithium battery, and the high-speed data acquisition module and excitation module are respectively connected to the lithium battery through multi-core explosion-proof cables. The electromagnetic ultrasonic transducer outside the explosion-proof box is connected, the intrinsically safe isolation module is connected to the wireless transmission module outside the explosion-proof box through an explosion-proof communication cable, and the wireless transmission module is wirelessly connected to the server; the wireless transmission module is enclosed in a metal shell, metal The shell is encapsulated with potting glue, and the wireless transmission module is connected to an antenna.

among them:

Excitation module: used to provide high frequency alternating current to the electromagnetic ultrasonic transducer.

Electromagnetic ultrasonic transducer: responsible for exciting and receiving ultrasonic signals, and transmitting the ultrasonic signals to the high-speed data acquisition module.

High-speed data acquisition module: responsible for converting the received ultrasonic signal into a digital signal and transmitting the digital signal to the intrinsically safe isolation module.

Intrinsically safe isolation module: the received digital signal is processed by the intrinsically safe circuit and transmitted to the wireless transmission module.

Wireless transmission module: The digital signal transmitted from the intrinsically safe isolation module is sent to the server wirelessly.

Server: Process the signal and calculate the thickness of the pipeline under test.

As a preferred solution:

The explosion-proof box is provided with a bell mouth, and a cable sleeve is arranged at the bell mouth.

The potting glue in the metal shell is silicone.

The shell of the electromagnetic ultrasonic transducer is made of stainless steel.

Epoxy resin is potted in the shell of the electromagnetic ultrasonic transducer.

The induction coil in the electromagnetic ultrasonic transducer is a butterfly coil; the butterfly coil adopts a double-layer FPCB structure for plate making, and has a double-layer butterfly coil structure on both sides.

The wireless method is any one of WIFI, GSM, and Bluetooth.

The explosion-proof box is provided with a dry reed switch circuit breaker protector.

The invention also includes an explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning on-line detection method, including the following steps:

(1) Attach the electromagnetic ultrasonic transducer to the designated point to be tested on the pipeline to be tested for fixed-point online testing.

(2) Connect the electromagnetic ultrasonic transducer to the excitation module and the high-speed data acquisition module in the explosion-proof box through a multi-core explosion-proof cable.

(3) The excitation module provides high-frequency alternating current for the induction coil in the electromagnetic ultrasonic transducer, excites ultrasonic waves, reflects multiple ultrasonic echoes through the inner wall of the pipeline, and then the electromagnetic ultrasonic transducer transmits the ultrasonic signals to high-speed data Acquisition module.

(4) The high-speed data acquisition module converts the received ultrasonic signal into a digital signal, and transmits this digital signal to the intrinsically safe isolation module for processing. The intrinsically safe isolation module processes the signal and transmits it to the wireless transmission module. The wireless transmission module The signal is transmitted wirelessly to the server, and the server calculates the thickness of the pipe under test.

(5) Observe whether the pipe thickness value measured by the system is stable. When the measured thickness value is stable, set the system to work at regular intervals to realize online monitoring of pipe thinning.

Beneficial effect

The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system of the present invention meets the explosion-proof requirements of pipeline safety monitoring in the explosive environment of chemical parks, breaks through the technical bottleneck of electromagnetic ultrasonic technology applied in explosive environments, and meets the GB 3836 explosion-proof standard. It solves the problem of pipeline safety monitoring in the chemical park and can be directly applied to the explosive environment of the chemical park to realize the real-time online monitoring and early warning function of the corrosion and thinning status of the oil and gas pipeline network. It fills the gap in the domestic market and has broad market application prospects.

Description of the drawings

Figure 1 is a schematic diagram of the structure of the present invention.

Figure 2 is a schematic diagram of part of the structure of the present invention.

Figure 3 is a framework diagram of the present invention.

Figure 4 is a signal waveform diagram used for pipeline thickness detection in the present invention.

In the picture, 1 explosion-proof box, 2 metal shell, 3 wireless transmission module, 4 antenna, 5 explosion-proof communication cable, 6 cable sleeve, 7 multi-core explosion-proof cable, 8 electromagnetic ultrasonic transducer, 9 dry reed switch circuit breaker protector .

The best mode of the invention

In order to make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be described clearly and completely in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments It is a part of the embodiments of the present invention, not all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work shall fall within the protection scope of the present invention.

The online detection system of the present invention includes an electromagnetic ultrasonic transducer 8. The multi-core explosion-proof cable 7 at the upper end of the electromagnetic ultrasonic transducer 8 passes through the bell mouth of the explosion-proof box 1 and is respectively connected with the high-speed data acquisition module and the excitation module enclosed in the explosion-proof box 1 connection. An intrinsically safe isolation module and a lithium battery are also placed in the explosion-proof box 1. The intrinsically safe isolation module is connected to the high-speed data acquisition module, and the lithium battery is respectively connected to the high-speed data acquisition module, excitation module and intrinsically safe isolation module. The lithium battery is used as the entire system Energy source. The intrinsically safe isolation module is connected to the wireless transmission module 3 outside the explosion-proof box 1 through the explosion-proof communication cable 5 passing through the bell mouth. The wireless transmission module 3 is encapsulated in a metal casing 2, and the metal casing 2 is encapsulated with silicone potting glue for water and dust prevention. The wireless transmission module 3 is connected to an antenna 4 to the outside, and the wireless transmission module 3 sends the received signal to the server through the antenna 4.

Among them, the bell mouth of the explosion-proof box 1 is also provided with a cable sleeve 6, and the design of the explosion-proof box 1 strictly complies with the requirements of the national standard. The explosion-proof box 1 is also provided with a dry reed switch circuit breaker 9, which is mainly used to make the entire detection system open when the cover of the explosion-proof box 1 is opened.

The shell of the electromagnetic ultrasonic transducer 8 here is made of stainless steel. The shell is potted with epoxy resin. After epoxy resin potting, the induction coil, permanent magnet and multi-core explosion-proof in the electromagnetic ultrasonic transducer 8 The cable 7 etc. are completely enclosed in the shell to form a whole. In this way, the induction coil is completely isolated from the outside world. Even the sparks caused by the breakdown of the induction coil during operation cannot be transmitted outside, thus preventing the induction coil from working in an explosive environment. The phenomenon of spark propagation. The induction coil in the electromagnetic ultrasonic transducer 8 of this embodiment is a butterfly coil, and the butterfly coil design can eliminate electromagnetic noise in the circuit loop and increase the effective detection area of the induction coil. Preferably, the induction coil adopts a double-layer FPCB structure for plate making, and adopts a double-layer butterfly coil design structure on both sides.

The above-mentioned excitation module is used to provide high-frequency alternating current to the electromagnetic ultrasonic transducer 8 to excite ultrasonic waves in the test piece.

The above-mentioned electromagnetic ultrasonic transducer 8 is responsible for exciting and receiving ultrasonic signals, and transmitting the ultrasonic signals to the high-speed data acquisition module.

The above-mentioned high-speed data acquisition module is responsible for converting the received ultrasonic signal into a digital signal and transmitting the digital signal to the intrinsically safe isolation module.

The function of the above-mentioned intrinsically safe isolation module is to process the received digital signal through the intrinsically safe circuit within it and then transmit it to the wireless transmission module 3.

The above-mentioned wireless transmission module 3 functions to wirelessly send the digital signal transmitted from the intrinsically safe isolation module to the server. The wireless mode can be any of the existing wireless transmission, such as WIFI, GSM, Bluetooth, etc.

The above-mentioned server processes the signal, calculates the thickness value of the pipeline under test, and realizes online monitoring of pipeline thinning.

Embodiments of the invention

The detection method of the above online detection system includes the following steps:

1. Relying on the suction force of the permanent magnet in the electromagnetic ultrasonic transducer 8, the electromagnetic ultrasonic transducer 8 is adsorbed on the designated measured point on the pipeline to be tested, and fixed-point online inspection is performed.

2. Connect the electromagnetic ultrasonic transducer 8 to the excitation module and the high-speed data acquisition module in the explosion-proof box 1 through the multi-core explosion-proof cable 7 respectively.

3. The excitation module provides high-frequency alternating current for the induction coil in the electromagnetic ultrasonic transducer 8, and induces eddy currents in the pipeline under test. The eddy currents generate Lorentz force and magnetostrictive force in a stable bias magnetic field. , Exciting ultrasonic waves under the action of alternating force. The excited ultrasonic wave propagates along the thickness direction of the pipeline, and reflects multiple ultrasonic echoes through the inner wall of the pipeline. The electromagnetic ultrasonic transducer 8 transmits the ultrasonic signal to the high-speed data acquisition module.

4. The high-speed data acquisition module converts the received ultrasonic signal into a digital signal, and transmits the digital signal to the intrinsically safe isolation module for processing. The intrinsically safe isolation module processes the signal and transmits it to the wireless transmission module 3. Wireless transmission module 3 Transmit the signal to the server wirelessly. The server obtains the time interval between two adjacent ultrasonic echoes by processing the signal, that is, the time for the ultrasonic wave to go back and forth in the thickness direction of the pipe, combined with the already calibrated ultrasonic wave in the pipe Calculate the thickness of the pipeline under test.

5. Observe whether the pipe thickness value measured by the system is stable. When the measured thickness value is stable, the system can be used to monitor the thickness of the pipe under test. This system can be set to work every certain time to realize online monitoring of pipeline thinning.

The detection system of the present invention is used to detect a CB-I type standard test block with a nominal thickness of 22 mm within the range of 1mm-7mm lift-off distance, and the detection result is shown in FIG. 4. It can be seen from the waveform that when the lift-off distance is increased to 6mm, the material thickness can still be detected effectively, and the detection accuracy is less than ±0.05mm, which can meet the pipeline thickness detection requirements in the refinery plant area.

Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, not to limit them; those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the above embodiments, or Some of the technical features are equivalently replaced; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

An explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion and thinning online detection system, including an electromagnetic ultrasonic transducer (8), a high-speed data acquisition module, an excitation module, an intrinsically safe isolation module, a wireless transmission module (3) and a lithium battery. It is characterized in that: the high-speed data acquisition module, excitation module, intrinsically safe isolation module and lithium battery are packaged in an explosion-proof box (1), and the high-speed data acquisition module, excitation module and intrinsically safe isolation module are all connected to the lithium battery. The data acquisition module and the excitation module are respectively connected to the electromagnetic ultrasonic transducer (8) outside the explosion-proof box (1) through the multi-core explosion-proof cable (7), and the intrinsically safe isolation module is connected to the explosion-proof box (1) through the explosion-proof communication cable (5) The wireless transmission module (3) is connected to the external wireless transmission module (3), and the wireless transmission module (3) is connected to the server wirelessly; the wireless transmission module (3) is enclosed in a metal casing (2), and the metal casing (2) is potted Adhesive package, the wireless transmission module (3) is connected to an antenna (4);

among them:

Excitation module: used to provide high-frequency alternating current to the electromagnetic ultrasonic transducer (8);

Electromagnetic ultrasonic transducer (8): responsible for exciting and receiving ultrasonic signals, and transmitting the ultrasonic signals to the high-speed data acquisition module;

High-speed data acquisition module: responsible for converting the received ultrasonic signal into a digital signal and transmitting the digital signal to the intrinsically safe isolation module;

Intrinsically safe isolation module: the received digital signal is processed by the intrinsically safe circuit and then transmitted to the wireless transmission module (3);

Wireless transmission module (3): The digital signal transmitted from the intrinsically safe isolation module is sent to the server wirelessly;

Server: Process the signal and calculate the thickness of the pipeline under test.
The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system according to claim 1, wherein the explosion-proof box (1) is provided with a bell mouth, and a cable sleeve (6) is provided at the bell mouth.
The flameproof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system according to claim 1, wherein the potting glue in the metal shell (2) is silicone.
The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system according to claim 1, wherein the shell of the electromagnetic ultrasonic transducer (8) is made of stainless steel.
The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion and thinning online detection system according to claim 1, wherein the shell of the electromagnetic ultrasonic transducer (8) is potted with epoxy resin.
The flameproof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system according to claim 1, wherein the induction coil in the electromagnetic ultrasonic transducer (8) is a butterfly coil.
The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion and thinning online detection system according to claim 6, wherein the butterfly coil adopts a double-layer FPCB structure for plate making, and has a double-layer butterfly coil structure on the front and back.
The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system according to claim 1, wherein the wireless method is any of WIFI, GSM, and Bluetooth.
The explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection system according to claim 1, characterized in that: the explosion-proof box (1) is provided with a reed switch circuit breaker (9).
An explosion-proof electromagnetic ultrasonic oil and gas pipeline corrosion thinning online detection method includes the following steps:

(1) Attach the electromagnetic ultrasonic transducer (8) to the designated test point on the pipeline to be tested for fixed-point online inspection;

(2) Connect the electromagnetic ultrasonic transducer (8) to the excitation module and the high-speed data acquisition module in the explosion-proof box (1) through the multi-core explosion-proof cable (7);

(3) The excitation module provides high-frequency alternating current for the induction coil in the electromagnetic ultrasonic transducer (8), excites ultrasonic waves, reflects multiple ultrasonic echoes through the inner wall of the pipe, and then the electromagnetic ultrasonic transducer (8) The ultrasonic signal is transmitted to the high-speed data acquisition module;

(4) The high-speed data acquisition module converts the received ultrasonic signal into a digital signal, and transmits this digital signal to the intrinsically safe isolation module for processing. The intrinsically safe isolation module processes the signal and transmits it to the wireless transmission module (3), The wireless transmission module (3) transmits the signal wirelessly to the server, and the server calculates the thickness value of the pipe under test;

(5) Observe whether the pipe thickness value measured by the system is stable. When the measured thickness value is stable, set the system to work at regular intervals to realize online monitoring of pipe thinning.