A corrosion monitoring system and method based on fixed-point thickness measurement

Abstract

The application discloses a kind of corrosion monitoring system and method based on fixed-point thickness measurement.The method of the present application stores the basic information of the device to be monitored in the fixed-point thickness measurement corrosion monitoring processing center, generates the equipment account and two-dimensional code, attaches the two-dimensional code to the device to be monitored, determines the measurement point of the device to be monitored and the initial measurement frequency to form the initial thickness monitoring plan, generates the thickness account of each measurement point by the fixed-point thickness measurement corrosion monitoring processing center, measures the wall thickness of the measurement point by the intelligent mobile terminal according to the initial thickness monitoring plan of the measurement point, and stores it in the fixed-point thickness measurement corrosion monitoring processing center, calculates and divides the monitoring level of the measurement point, determines the thickness frequency according to the monitoring level and carries out corrosion monitoring warning.The application divides the monitoring level of the measurement point by using multiple parameters, updates the thickness plan and corrosion risk warning, realizes the integrated management of equipment corrosion monitoring data, and ensures the safe operation of the device.

Description

Technical Field

[0001] This invention relates to the field of corrosion technology for oil refining and chemical plant equipment, specifically to a corrosion monitoring system and method based on fixed-point thickness measurement. Background Technology

[0002] Equipment corrosion and pipeline corrosion are prominent issues affecting the safe operation of refining and chemical plants, seriously impacting their operational stability. It is necessary to monitor the corrosion status of equipment and pipelines in the refining and chemical process in real time and take effective protective and control measures before serious damage to equipment and pipelines occurs due to corrosion.

[0003] Ultrasonic thickness measurement, currently the most widely used corrosion monitoring method, is characterized by its real-time simplicity, low cost, direct and clear monitoring results, and high reliability. It is frequently used in corrosion monitoring of refining and chemical plants. However, when using ultrasonic thickness measurement to monitor the corrosion of equipment and pipelines in modern large-scale refining and chemical plants, hundreds or even thousands of measurement points need to be established. This results in a large amount of data for such monitoring. At present, the operation and management of ultrasonic thickness measurement-based monitoring still have many shortcomings. For example, monitoring data requires manual processing and entry, which is inefficient and prone to errors; data processing requires manual review of original records, making it impossible to provide immediate feedback after on-site measurements; and the formulation and adjustment of thickness measurement plans rely on expert experience, lacking scientific basis, leading to widespread missed and over-measurements.

[0004] Experts and scholars have solved the problem of automatic uploading and recording of thickness measurement data through research on intelligent thickness gauges, avoiding the influence of human factors on the measurement of equipment and pipe thickness, and improving the efficiency of fixed-point thickness measurement. Utility model patent CN 204228127 U discloses a wireless intelligent thickness gauge, including a main unit and a wireless ultrasonic probe. The main unit is equipped with an ultrasonic communication terminal, and the wireless ultrasonic probe communicates wirelessly with the ultrasonic communication terminal. The main unit processes the collected thickness data. The main unit includes a display screen, which is an LCD touch screen. Using a wireless ultrasonic probe and wireless transmission, the collected signals are directly transmitted to the main unit. This eliminates the need for wiring between the main unit and the probe, and also eliminates the need for manual data recording, improving work efficiency while avoiding the influence of human factors on the thickness measurement results. Utility model patent CN 206469863 U discloses a multi-functional integrated inspection terminal device for pressure vessels and pressure pipelines. This multi-functional integrated inspection terminal device consists of three modules: an application software module, an automatic identification module, and a thickness measurement module. The application software module organically combines the automatic identification module and the thickness measurement module, thereby quickly acquiring the basic information of the equipment, realizing accurate recording of thickness measurement data and location, improving the quality and collection efficiency of thickness measurement data, eliminating the need for manual entry of thickness measurement data, and making the communication of thickness measurement data information more timely and accurate.

[0005] Furthermore, relevant experts and scholars have studied methods for processing thickness measurement data of equipment and pipelines. Invention patent CN103499438B discloses a material adaptability evaluation method based on remaining service life. This method predicts the remaining service life of the equipment; compares the predicted remaining service life with the expected service life; and issues an alarm when the remaining service life is less than the user's expected service life, further analyzing the corrosion rate; if the corrosion rate exceeds the protection value, it recommends material upgrades. Invention patent CN 112014303A discloses a corrosion early warning method and device for equipment components. This method acquires raw multi-type information data of the component to be monitored, determines the corrosion rate based on the multi-type information data, and calculates the current remaining wall thickness of the component based on the corrosion rate and multi-type information data. Then, based on the component type and pressure type of the component to be monitored, the minimum allowable wall thickness of the component is obtained according to a preset method. Based on the current wall thickness, minimum allowable wall thickness, and corrosion rate, the remaining service life is calculated. Finally, based on a preset intended continuous service time and remaining service life, a corrosion early warning is issued, achieving automated, scientific, and effective corrosion early warning for equipment components, which helps equipment managers formulate targeted plans and timely response measures.

[0006] However, the aforementioned methods rely solely on the corrosion rate or remaining life of equipment and pipelines for corrosion risk early warning, lacking reliability and failing to fully utilize thickness measurement data. They do not establish a closed-loop feedback mechanism for corrosion monitoring based on the analysis results of equipment and pipeline corrosion rates and remaining lifespan, and lack systematic processing and application of fixed-point thickness measurement data. Therefore, there is an urgent need to propose a corrosion monitoring system and method based on fixed-point thickness measurement to fully monitor the corrosion status of equipment and pipelines using fixed-point thickness measurement data and issue early warnings, thereby improving the corrosion monitoring level of refining and chemical plants. Summary of the Invention

[0007] In response to the current low level of corrosion monitoring in refining and chemical plants, this invention proposes a corrosion monitoring system and method based on fixed-point thickness measurement. This system measures the absolute thinning amount, relative thinning amount, thinning rate, and remaining life at each measurement point on the monitored device. The monitoring level of each measurement point is comprehensively evaluated, and the thickness measurement plan for each point is adjusted in a timely manner. This achieves standardized collection and batch processing of thickness measurement data from the monitored device, reduces the influence of human factors in the corrosion monitoring level assessment process, improves the corrosion monitoring level of refining and chemical plants, and helps ensure the safe operation of these plants.

[0008] The present invention specifically adopts the following technical solution:

[0009] A corrosion monitoring system based on fixed-point thickness measurement includes a fixed-point thickness measurement corrosion monitoring and processing center and an intelligent mobile terminal;

[0010] The fixed-point thickness measurement corrosion monitoring and processing center is used for basic information of reservoir monitoring devices and thickness measurement records of measurement points, generating QR codes for monitoring devices, acquiring thickness measurement data from smart mobile terminals in real time, and analyzing and evaluating measurement points.

[0011] The intelligent mobile terminal is equipped with a display, a barcode scanner, a thickness gauge, and a control center. The display is used to show information about the monitoring level A measurement points on the device to be monitored. The barcode scanner is used to scan the QR code on the device to be monitored to obtain the basic information of the device. The thickness gauge is used to measure the wall thickness at each measurement point on the device to be monitored and transmit and store it in real time to the fixed-point thickness measurement corrosion monitoring and processing center.

[0012] Preferably, the display, barcode scanner, and thickness gauge are connected to the control center, and the intelligent mobile terminal is communicatively connected to the fixed-point thickness measurement corrosion monitoring and processing center.

[0013] A corrosion monitoring method based on fixed-point thickness measurement, employing the corrosion monitoring system based on fixed-point thickness measurement as described above, is applicable to refining and chemical equipment and pipelines, and specifically includes the following steps:

[0014] Step 1: Obtain the basic information of the device to be monitored and store it in the fixed-point thickness measurement corrosion monitoring and processing center to generate the equipment ledger of the device to be monitored.

[0015] Step 2: Use the fixed-point thickness measurement corrosion monitoring and processing center to generate a QR code for the device to be monitored, and attach the QR code to the device to be monitored.

[0016] Step 3: Select multiple measurement points on the device to be monitored for thickness measurement, determine the initial measurement frequency of each measurement point, formulate an initial thickness measurement monitoring plan for each measurement point, record each measurement point in the basic information stored in the fixed-point thickness measurement corrosion monitoring and processing center, and generate a thickness measurement ledger for each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center.

[0017] Step 4: According to the initial thickness measurement and monitoring plan for each measurement point, use a smart mobile terminal to measure the wall thickness at each measurement point on time and transmit it to the fixed-point thickness measurement and corrosion monitoring and processing center. Store the wall thickness measured at each measurement point each time in the thickness measurement log of each measurement point and update the thickness measurement log of each measurement point.

[0018] Step 5: After completing the initial thickness measurement monitoring of the device to be monitored according to the initial thickness measurement monitoring plan for each measurement point, retrieve the thickness measurement records for each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center, and determine the monitoring level for each measurement point. This specifically includes the following steps:

[0019] Step 5.1: Use the fixed-point thickness measurement corrosion monitoring and processing center to obtain the thickness measurement log of each measurement point and determine the wall thickness obtained at each measurement time at the measurement point.

[0020] Step 5.2: Calculate the absolute thinning amount WT, relative thinning amount RWT, total thinning rate TR, and remaining life RL for each measurement point.

[0021] The formula for calculating the absolute thinning amount (WT) at the measurement point is:

[0022] WT = max(TH1 - TH) N ,0) (1)

[0023] In the formula, TH1 is the wall thickness at the measurement point during the first measurement, TH N The wall thickness at the Nth measurement point;

[0024] The formula for calculating the relative thinning amount (RWT) at the measurement point is:

[0025]

[0026] The formula for calculating the total thinning rate TR at the measurement points is:

[0027] TR = α × TR N +β×TR A (3)

[0028] In formula (3), α is the first calculation coefficient for the total thinning rate, β is the second calculation coefficient for the total thinning rate, and TR N TR is the thinning rate at the Nth measurement point. A Let TR be the integral average thinning rate at the measurement point, where TR is the thinning rate at the Nth measurement point. N As shown in formula (4), the integral average thinning rate TR at the measurement point A As shown in formula (5):

[0029]

[0030]

[0031] In the formula, TH N-1 t represents the wall thickness at the (N-1)th measurement point; N The time t is the time for the Nth measurement of a measurement point. N-1 Let t1 be the time of the (N-1)th measurement at point N, and TR be the time of the (N-1)th measurement at point N. i The thinning rate at the i-th measurement point;

[0032] The formula for calculating the remaining lifetime (RL) of the measurement point is:

[0033]

[0034] In the formula, TH min The minimum pressure-bearing wall thickness of the device to be measured;

[0035] Step 5.3: For each measurement point, the monitoring level is divided according to the absolute thinning amount WT, relative thinning amount RWT, total thinning rate TR and remaining life RL of each measurement point.

[0036] If the relative thinning amount RWT of the measurement point is ≤20%, the total thinning rate TR is ≤0.1mm / a, and the remaining lifespan RL is ≥8 years, then the monitoring level of the measurement point is classified as Level C; if the measurement point meets either the relative thinning amount RWT>40% or the total thinning rate TR>0.3mm / a and the absolute thinning amount WT>1mm, or if the measurement point meets the remaining lifespan RL<1.5 years, then the monitoring level of the measurement point is classified as Level A; except for the cases classified as Level A and Level C, the monitoring level of the measurement point is classified as Level B in all other cases.

[0037] Step 6: Based on the monitoring level of each measurement point, redetermine the thickness measurement frequency of each measurement point and update the thickness measurement log of each measurement point.

[0038] Step 7: Use the fixed-point thickness measurement corrosion monitoring and processing center to retrieve and update the thickness measurement records of each measurement point, and push the thickness measurement records of measurement points with monitoring level A to the smart mobile terminal. Professional technicians can view the thickness measurement records of the measurement points on the smart mobile terminal, analyze each measurement point with monitoring level A, and formulate anti-corrosion measures.

[0039] Preferably, in step 1, if the device to be monitored is a refining and chemical equipment, the basic information obtained includes the individual equipment diagram and equipment ledger of the refining and chemical equipment; if the device to be monitored is a pipeline, the basic information obtained includes the single-line diagram and pipeline ledger of the pipeline.

[0040] Preferably, the equipment ledger of the pipeline records the pipeline's number, name, starting point, ending point, material, internal flowing medium, design temperature, design pressure, operating temperature, operating pressure, pipeline length, number of welds, number of elbows, anti-corrosion and insulation materials, pressure rating, safety rating, equipment importance rating, commissioning time, maintenance records, and manufacturing unit.

[0041] Preferably, when the refining equipment is a furnace, the equipment ledger records the furnace body name, process number, internal medium, equipment specifications, heat load, design pressure, design temperature, outlet pressure, outlet temperature, inlet pressure, inlet temperature, furnace tube material, furnace tube specifications, number of radiant furnace tubes, number of convection furnace tubes, elbow type, number of elbows, elbow material, highest temperature inside the furnace, flue temperature, number and model of burners, insulation method, equipment importance level, commissioning time, maintenance records, and manufacturing unit;

[0042] When the refining equipment is a tower-type equipment, the equipment ledger records the tower's name, process number, specifications, material, tray structure parameters, tower top cover dimensions and material, tower bottom cover dimensions and material, tower top design temperature and design pressure, tower bottom design temperature and design pressure, tower top operating pressure and operating temperature, tower bottom operating pressure and operating temperature, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0043] When the refining equipment is a container-type equipment, the equipment ledger records the container's name, process number, storage medium, specifications, material, design temperature and design pressure, operating temperature and operating pressure, anti-corrosion and heat insulation materials, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0044] When the refining equipment is a heat exchanger, the equipment ledger records the name, model, process number, material, tube bundle and tube sheet dimensions, internal medium, tube side design pressure and design temperature, shell side design pressure and design temperature, tube side operating pressure and operating temperature, shell side operating pressure and operating temperature, vessel type, heat exchanger tube specifications and data, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0045] When the refining equipment is a reactor, the equipment ledger records the reactor's name, process number, model, volume, test pressure value, weight, internal medium, design temperature and design pressure, inlet temperature and outlet temperature, inlet pressure and outlet pressure, material, insulation material thickness, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0046] Preferably, in step 2, the QR code corresponds one-to-one with the device to be monitored. By scanning the QR code with a smart mobile terminal, the device ledger of the device to be monitored can be retrieved in real time, and the basic information of the device to be monitored can be obtained.

[0047] Preferably, in step 2, the QR code is attached to the surface of the device to be monitored by pasting, hanging, or inkjet printing.

[0048] Preferably, in step 3, the measurement points of the device to be monitored are selected according to the pipeline inspection layout requirements in SY / T 6553-2003, and the initial measurement frequency of the device to be monitored is set according to the pipeline inspection frequency in SY / T 6553-2003.

[0049] Preferably, the thickness measurement log includes the equipment name, drawing number, measurement point location number, diameter, wall thickness, material, internal medium, design temperature and design pressure, operating temperature and operating pressure, commissioning time, measurement time and measured wall thickness, and next measurement time for the device to be monitored.

[0050] Preferably, in step 4, the QR code on the device to be monitored is scanned using a barcode scanner on a smart mobile terminal to obtain the location information of the measurement point. Then, the wall thickness at the measurement point is measured using a thickness gauge, and the measured wall thickness is transmitted in real time to the fixed-point thickness measurement corrosion monitoring and processing center to realize the automatic association between the thickness measurement location and the thickness measurement information.

[0051] Preferably, in step 5.2, the first calculation coefficient α of the total thinning rate is set to 0.75 and the second calculation coefficient β of the total thinning rate is set to 0.25.

[0052] Preferably, in step 5.2, if the device to be monitored is a pipeline, the minimum pressure-bearing wall thickness of the device to be monitored is determined according to the Petrochemical Pipeline Design and Equipment Selection Specification in SY / T 3059-2012; if the device to be monitored is refining equipment, the minimum pressure-bearing wall thickness of the device to be monitored is determined according to GB150.3-2011.

[0053] Preferably, in step 5.2, when the device to be monitored is a pipe, and the pipe diameter is not less than 100mm and the wall thickness measured in the Nth time does not exceed 3mm, the remaining life of the pipe is directly determined to be 0 without calculation.

[0054] Preferably, in step 6, if the monitoring level of the measurement point is level A, the wall thickness of the measurement point is measured every 3 to 6 months; if the monitoring level of the measurement point is level B, the wall thickness of the measurement point is measured every 6 months to 2 years; if the monitoring level of the measurement point is level C, the wall thickness of the measurement point is measured every 4 years or in each operating cycle of the device to be monitored.

[0055] The beneficial effects of this invention are:

[0056] This invention proposes a corrosion monitoring system and method based on fixed-point thickness measurement. The system utilizes a smart mobile terminal to accurately acquire the wall thickness at each measurement point on the monitored device and transmits this data in real-time to the fixed-point thickness measurement corrosion monitoring processing center. This center performs batch processing to promptly obtain the absolute thinning amount, relative thinning amount, thinning rate, and remaining lifespan of each measurement point. Based on these parameters, the monitoring level of each measurement point is accurately determined, and the thickness measurement plan is adjusted accordingly, thus improving the reliability of the monitoring level determination.

[0057] This invention systematizes the fixed-point thickness measurement monitoring workflow, and uses the measurement results of fixed-point thickness measurement to monitor the corrosion of refining and chemical plants. It realizes a standardized process for thickness measurement data acquisition, processing and feedback, which greatly reduces the impact of human factors in the corrosion monitoring process based on thickness measurement data, improves the corrosion monitoring level of refining and chemical plants, and effectively ensures the safe operation of refining and chemical plants. Attached Figure Description

[0058] Figure 1 This is a flowchart of a corrosion monitoring method based on fixed-point thickness measurement according to the present invention.

[0059] Figure 2 This is a single-line diagram of the constant top circulation tower pipeline. Detailed Implementation

[0060] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0061] Example 1

[0062] This embodiment proposes a corrosion monitoring system and method based on fixed-point thickness measurement. The system acquires thickness measurement data at various measurement points on the device under monitoring, including a fixed-point thickness measurement corrosion monitoring and processing center and a smart mobile terminal, with communication connections between them.

[0063] The fixed-point thickness measurement corrosion monitoring and processing center is used for basic information of reservoir monitoring devices and thickness measurement records of measurement points, generating QR codes for monitoring devices, acquiring thickness measurement data from smart mobile terminals in real time, and analyzing and evaluating measurement points. The smart mobile terminal is equipped with a display, barcode scanner, thickness gauge, and control center. The display, barcode scanner, and thickness gauge are all connected to the control center. The display shows information about measurement points on the monitoring device with a monitoring level of A. The barcode scanner scans the QR code on the monitoring device to obtain its basic information. The thickness gauge measures the wall thickness at each measurement point on the monitoring device and transmits and stores the data in real time to the fixed-point thickness measurement corrosion monitoring and processing center.

[0064] This embodiment proposes a corrosion monitoring method based on fixed-point thickness measurement, such as... Figure 1 As shown, the corrosion monitoring system based on fixed-point thickness measurement described above is suitable for corrosion monitoring of refining equipment and pipelines in petrochemical enterprises. The specific steps include:

[0065] Step 1: Obtain the basic information of the device to be monitored and store it in the fixed-point thickness measurement corrosion monitoring and processing center to generate the equipment ledger of the device to be monitored.

[0066] If the device to be monitored is a pipeline, the basic information obtained includes a single-line diagram of the pipeline and a pipeline ledger. The pipeline's equipment ledger records the pipeline's number, name, starting point, ending point, material, internal flowing medium, design temperature, design pressure, operating temperature, operating pressure, pipeline length, number of welds, number of elbows, anti-corrosion and insulation materials, pressure rating, safety rating, equipment importance rating, commissioning time, maintenance records, and manufacturing unit.

[0067] If the device to be monitored is a refining and chemical equipment, the basic information obtained includes individual equipment diagrams and equipment ledgers of the refining and chemical equipment.

[0068] When the refining equipment is a furnace, the equipment ledger records the furnace body name, process number, internal medium, equipment specifications, heat load, design pressure, design temperature, outlet pressure, outlet temperature, inlet pressure, inlet temperature, furnace tube material, furnace tube specifications, number of radiant furnace tubes, number of convection furnace tubes, elbow type, number of elbows, elbow material, highest temperature inside the furnace, flue temperature, number and model of burners, insulation method, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0069] When the refining equipment is a tower type, the equipment ledger records the tower's name, process number, specifications, material, tray structure parameters, tower top cover dimensions and material, tower bottom cover dimensions and material, tower top design temperature and design pressure, tower bottom design temperature and design pressure, tower top operating pressure and operating temperature, tower bottom operating pressure and operating temperature, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0070] When the refining equipment is a container type, the equipment ledger records the container's name, process number, internal storage medium, specifications, material, design temperature and pressure, operating temperature and pressure, anti-corrosion and insulation materials, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0071] When the refining and chemical equipment is a heat exchanger, the equipment ledger records the name, model, process number, material, tube bundle and tube sheet dimensions, internal medium, tube-side design pressure and design temperature, shell-side design pressure and design temperature, tube-side operating pressure and operating temperature, shell-side operating pressure and operating temperature, vessel type, heat exchanger tube specifications and data, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0072] When the refining and chemical equipment is a reactor, the equipment ledger records the reactor's name, process number, model, volume, test pressure value, weight, internal medium, design temperature and design pressure, inlet temperature and outlet temperature, inlet pressure and outlet pressure, material, insulation material thickness, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

[0073] Step 2: Use the fixed-point thickness measurement corrosion monitoring and processing center to generate a QR code for the device to be monitored. Each QR code corresponds to a specific device. The QR code is attached to the surface of the device by pasting, hanging, or inkjet printing. By scanning the QR code with a smart mobile terminal, the device's equipment ledger can be retrieved in real time to obtain the device's basic information.

[0074] Step 3: Set up multiple measurement points for thickness measurement on the device to be monitored. Select the measurement points of the device to be monitored according to the pipeline inspection layout requirements in SY / T 6553-2003. Then set the initial measurement frequency of the measurement points of the device to be monitored according to the pipeline inspection frequency in SY / T 6553-2003. Develop an initial thickness measurement monitoring plan for each measurement point. Record each measurement point in the basic information stored in the fixed-point thickness measurement corrosion monitoring and processing center. Use the fixed-point thickness measurement corrosion monitoring and processing center to generate a thickness measurement ledger for each measurement point.

[0075] The thickness measurement log includes the equipment name, drawing number, measurement point location number, diameter, wall thickness, material, internal medium, design temperature and design pressure, operating temperature and operating pressure, commissioning time, measurement time and measured wall thickness, and next measurement time for the device to be monitored.

[0076] Step 4: According to the initial thickness measurement monitoring plan for each measurement point, use the barcode scanner of the smart mobile terminal to scan the QR code on the device to be monitored to obtain the location information of the measurement point. Then, use the thickness gauge of the smart mobile terminal to measure the wall thickness of the measurement point on time and transmit it to the fixed-point thickness measurement corrosion monitoring and processing center. While automatically associating the thickness measurement location with the thickness measurement information, store the wall thickness measured at each measurement point in the thickness measurement log of each measurement point and update the thickness measurement log of each measurement point.

[0077] Step 5: After completing the initial thickness measurement monitoring of the device to be monitored according to the initial thickness measurement monitoring plan for each measurement point, retrieve the thickness measurement records for each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center, and determine the monitoring level for each measurement point. This specifically includes the following steps:

[0078] Step 5.1: Use the fixed-point thickness measurement corrosion monitoring and processing center to obtain the thickness measurement log of each measurement point and determine the wall thickness obtained at each measurement time at the measurement point.

[0079] Step 5.2: Calculate the absolute thinning amount WT, relative thinning amount RWT, total thinning rate TR, and remaining life RL for each measurement point.

[0080] The formula for calculating the absolute thinning amount (WT) at the measurement point is:

[0081] WT = max(TH1 - TH) N ,0) (1)

[0082] In the formula, TH1 is the wall thickness at the measurement point during the first measurement, TH N The wall thickness is measured at the Nth measurement point.

[0083] The formula for calculating the relative thinning amount (RWT) at the measurement point is:

[0084]

[0085] The formula for calculating the total thinning rate TR at the measurement points is:

[0086] TR = α × TR N +β×TR A (3)

[0087] In formula (3), α is the first calculation coefficient of the total thinning rate, and β is the second calculation coefficient of the total thinning rate. In this embodiment, the first calculation coefficient α of the total thinning rate is set to 0.75, and the second calculation coefficient β of the total thinning rate is set to 0.25. N TR is the thinning rate at the Nth measurement point. A Let TR be the integral average thinning rate at the measurement point, where TR is the thinning rate at the Nth measurement point. N As shown in formula (4), the integral average thinning rate TR at the measurement point A As shown in formula (5):

[0088]

[0089]

[0090] In the formula, TH N-1 t represents the wall thickness at the (N-1)th measurement point; N The time t is the time for the Nth measurement of a measurement point. N-1 Let t1 be the time of the (N-1)th measurement at point N, and TR be the time of the (N-1)th measurement at point N. i The thinning rate at the i-th measurement point;

[0091] The formula for calculating the remaining lifetime (RL) of the measurement point is:

[0092]

[0093] In the formula, TH min The minimum pressure-bearing wall thickness of the device to be measured is specified. When the device to be monitored is a pipeline, the minimum pressure-bearing wall thickness of the device to be monitored is determined according to the Petrochemical Pipeline Design and Equipment Selection Specification in SY / T3059-2012. When the device to be monitored is a refining and chemical equipment, the minimum pressure-bearing wall thickness of the device to be monitored is determined according to GB150.3-2011.

[0094] Furthermore, when the device to be monitored is a pipeline, and the pipeline diameter is not less than 100mm and the wall thickness of the Nth measurement does not exceed 3mm, then there is no need to calculate the remaining life of each measurement point, and the remaining life of each measurement point is directly determined to be 0, that is, the remaining life of the pipeline is 0.

[0095] Step 5.3: For each measurement point, the monitoring level is classified according to the absolute thinning amount WT, relative thinning amount RWT, total thinning rate TR, and remaining life RL of each measurement point.

[0096] If the relative thinning amount RWT of the measurement point is ≤20%, the total thinning rate TR is ≤0.1mm / a, and the remaining lifespan RL is ≥8 years, then the monitoring level of the measurement point is classified as Level C; if the measurement point meets either the relative thinning amount RWT>40% and the total thinning rate TR>0.3mm / a and the absolute thinning amount WT>1mm, or if the measurement point meets the remaining lifespan RL<1.5 years, then the monitoring level of the measurement point is classified as Level A; except for the cases classified as Level A and Level C, the monitoring level of the measurement point is classified as Level B in all other cases.

[0097] Step 6: Based on the monitoring level of each measurement point, redetermine the thickness measurement frequency for each measurement point and update the thickness measurement log for each measurement point. If the monitoring level of a measurement point is Level A, the wall thickness of the measurement point shall be measured every 3 to 6 months; if the monitoring level of a measurement point is Level B, the wall thickness of the measurement point shall be measured every 6 months to 2 years; if the monitoring level of a measurement point is Level C, the wall thickness of the measurement point shall be measured every 4 years or during each operating cycle of the device to be monitored.

[0098] Step 7: Use the fixed-point thickness measurement corrosion monitoring and processing center to retrieve and update the thickness measurement records of each measurement point, and push the thickness measurement records of measurement points with monitoring level A to the smart mobile terminal. Professional technicians can view the thickness measurement records of the measurement points on the smart mobile terminal, analyze each measurement point with monitoring level A, and formulate anti-corrosion measures.

[0099] Example 2

[0100] This embodiment takes the circulating return section pipeline at the top of the atmospheric pressure tower of a refining and chemical enterprise as an example, and adopts a corrosion monitoring system and method based on fixed-point thickness measurement proposed in this invention, specifically including the following steps:

[0101] Step 1: Obtain the basic information of the constant-top circulating tower pipeline and store it in the fixed-point thickness measurement and corrosion monitoring and processing center. The basic information includes the single-line diagram and equipment ledger of the constant-top circulating tower pipeline. The single-line diagram of the pipeline is as follows: Figure 2 As shown in Table 1, the pipeline equipment ledger records the pipeline number, name, starting point, ending point, material, internal flowing medium, design temperature, design pressure, operating temperature, operating pressure, pipeline length, number of welds, number of elbows, anti-corrosion and insulation materials, pressure rating, safety rating, equipment importance rating, commissioning time, maintenance records, and manufacturing unit.

[0102] Table 1. Inventory of the Permanent Top Circulation Tower Pipeline and Equipment

[0103]

[0104] Step 2: Use the fixed-point thickness measurement corrosion monitoring and processing center to generate a QR code for the constant top circulation tower pipeline. Paste the QR code on the surface of the constant top circulation tower pipeline. Use a smart mobile terminal to scan the QR code to retrieve the equipment ledger of the constant top circulation tower pipeline in real time and obtain the basic information of the constant top circulation tower pipeline.

[0105] Step 3: Set measurement points on the constant top circulation tower pipeline according to SY / T 6553-2003. At the same time, generate the thickness measurement log for each measurement point according to the initial measurement frequency set in SY / T6553-2003, as shown in Table 2.

[0106] Table 2 Equipment Ledger for the Constant Top Circulation Tower Pipeline

[0107]

[0108] In this embodiment, five sets of measurement positions are set on the constant top circulation tower pipeline according to the pipeline inspection layout requirements in SY / T 6553-2003. Each set of measurement positions includes four measurement points, which are set at the 3 o'clock, 6 o'clock, 9 o'clock and 12 o'clock positions on the constant top circulation tower pipeline. The initial measurement frequency of the measurement points to be monitored is set according to the pipeline inspection frequency in SY / T 6553-2003. An initial thickness measurement monitoring plan is formulated for each measurement point. The set measurement points are recorded in the basic information stored in the fixed-point thickness measurement corrosion monitoring and processing center. The fixed-point thickness measurement corrosion monitoring and processing center is used to generate a thickness measurement ledger for each measurement point.

[0109] Step 4: According to the initial thickness monitoring plan for each measurement point, use the barcode scanner of the smart mobile terminal to scan the QR code on the constant top circulation tower pipeline to obtain the location information of the measurement point. Then, use the thickness gauge of the smart mobile terminal to measure the wall thickness of the measurement point on time and transmit it to the fixed-point thickness measurement corrosion monitoring and processing center. While automatically associating the thickness measurement location with the thickness measurement information, store the wall thickness measured at each measurement point in the thickness measurement log of each measurement point and update the thickness measurement log of each measurement point.

[0110] Step 5: After completing the initial thickness measurement monitoring of the circulating tower pipeline according to the initial thickness measurement monitoring plan for each measurement point, retrieve the thickness measurement records for each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center, and determine the corrosion monitoring level for each measurement point. This embodiment uses measurement point number W017205 as an example to illustrate the detailed process of determining the monitoring level for each measurement point, specifically including the following steps:

[0111] Step 5.1: Obtain the thickness measurement log of each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center, and determine the wall thickness obtained at each measurement time at the measurement point. The thickness measurement data of measurement point number W017205 is shown in Table 3.

[0112] Table 3 Thickness measurement data at measurement point W017205

[0113]

[0114] Step 5.2: Calculate the absolute thinning amount WT, relative thinning amount RWT, total thinning rate TR and remaining life RL of each measurement point using formulas (1) to (6). The absolute thinning amount WT of measurement point W017205 is 4.93 mm, the relative thinning amount RWT is 34.64%, the total thinning rate TR is 3.9 mm / a, and the remaining life RL is 1.2 y.

[0115] Step 5.3: Based on the absolute thinning amount WT of measurement point W017205 being 4.93 mm, the relative thinning amount RWT being 34.64%, the total thinning rate TR being 3.9 mm / a, and the remaining lifespan RL being 1.2 years, and considering that when the relative thinning amount RWT of the measurement point is ≤20%, the total thinning rate TR is ≤0.1 mm / a, and the remaining lifespan RL is ≥8 years, the monitoring level of the measurement point is determined to be Class C; when the measurement point meets either the relative thinning amount RWT >40% or the total thinning rate TR >0.3 mm / a and the absolute thinning amount WT >1 mm, or the measurement point meets the remaining lifespan RL <1.5 years, the monitoring level of the measurement point is determined to be Class A; excluding the cases of Class A and Class C, all other cases are determined to be Class B. Therefore, the monitoring level of measurement point W017205 is determined to be Class A.

[0116] Step 6: Based on the monitoring level of measurement point W017205, redetermine the thickness measurement frequency of measurement point W017205 to once every 3 months.

[0117] Step 7: Use the fixed-point thickness measurement corrosion monitoring and processing center to retrieve the updated thickness measurement log of the constant top circulation tower pipeline, as shown in Table 4. Push the thickness measurement log of the measurement points with monitoring level A to the smart mobile terminal. Professional technicians can view the thickness measurement log of the measurement points on the smart mobile terminal, analyze each measurement point with monitoring level A, and formulate anti-corrosion measures.

[0118] Table 4. Updated Thickness Measurement Records of the Constant Temperature Circulation Tower Pipeline

[0119]

[0120] According to Table 4, only the monitoring level of measurement point W017205 in the updated circulating tower pipeline was classified as Level A. The fixed-point thickness measurement corrosion monitoring and processing center pushed the thickness measurement log of measurement point W017205 to the smart mobile terminal. Professional technicians can view the thickness measurement log of the measurement point on the smart mobile terminal, analyze measurement point W017205, and formulate anti-corrosion measures.

[0121] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A corrosion monitoring method based on fixed-point thickness measurement, characterized in that, A corrosion monitoring system based on fixed-point thickness measurement is adopted, which includes a fixed-point thickness measurement corrosion monitoring and processing center and an intelligent mobile terminal. The fixed-point thickness measurement corrosion monitoring and processing center is used for basic information of reservoir monitoring devices and thickness measurement records of measurement points, generating QR codes for monitoring devices, acquiring thickness measurement data from smart mobile terminals in real time, and analyzing and evaluating measurement points. The intelligent mobile terminal is equipped with a display, a barcode scanner, a thickness gauge, and a control center. The display is used to show information about the monitoring level A measurement points on the device to be monitored. The barcode scanner is used to scan the QR code on the device to be monitored to obtain the basic information of the device. The thickness gauge is used to measure the wall thickness at each measurement point on the device to be monitored and transmit and store it in real time to the fixed-point thickness measurement corrosion monitoring and processing center. The display, barcode scanner, and thickness gauge are connected to the control center, and the intelligent mobile terminal is connected to the fixed-point thickness measurement corrosion monitoring and processing center. Applicable to refining equipment and pipelines, specifically including the following steps: Step 1: Obtain the basic information of the device to be monitored and store it in the fixed-point thickness measurement corrosion monitoring and processing center to generate the equipment ledger of the device to be monitored. Step 2: Use the fixed-point thickness measurement corrosion monitoring and processing center to generate a QR code for the device to be monitored, and attach the QR code to the device to be monitored. Step 3: Select multiple measurement points on the device to be monitored for thickness measurement, determine the initial measurement frequency of each measurement point, formulate an initial thickness measurement monitoring plan for each measurement point, record each measurement point in the basic information stored in the fixed-point thickness measurement corrosion monitoring and processing center, and generate a thickness measurement ledger for each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center. Step 4: According to the initial thickness measurement and monitoring plan for each measurement point, use a smart mobile terminal to measure the wall thickness at each measurement point on time and transmit it to the fixed-point thickness measurement and corrosion monitoring and processing center. Store the wall thickness measured at each measurement point each time in the thickness measurement log of each measurement point and update the thickness measurement log of each measurement point. Step 5: After completing the initial thickness measurement monitoring of the device to be monitored according to the initial thickness measurement monitoring plan for each measurement point, retrieve the thickness measurement records for each measurement point using the fixed-point thickness measurement corrosion monitoring and processing center, and determine the monitoring level for each measurement point. This specifically includes the following steps: Step 5.1: Use the fixed-point thickness measurement corrosion monitoring and processing center to obtain the thickness measurement log of each measurement point and determine the wall thickness obtained at each measurement time at the measurement point. Step 5.2: Calculate the absolute thinning amount at each measurement point. Relative thinning amount Total thinning rate and remaining lifespan ; Absolute thinning at measurement points The calculation formula is: （1） In the formula, The wall thickness at the measurement point during the first measurement. The wall thickness at the Nth measurement point; Relative thinning at measurement points The calculation formula is: （2） Total thinning rate at measurement points The calculation formula is: （3） In formula (3), The first calculation coefficient for the total thinning rate is... The second calculation coefficient for the total thinning rate. The thinning rate at the Nth measurement point. Let be the integral average thinning rate of the measurement points, where is the thinning rate at the Nth measurement point. As shown in formula (4), the integral average thinning rate at the measurement points As shown in formula (5): （4） （5） In the formula, The wall thickness at the (N-1)th measurement point; The time for the Nth measurement of the measurement point. The time of the (N-1)th measurement of the measurement point. The time for the Nth measurement of the measurement point. The thinning rate at the i-th measurement point; Remaining lifespan of measurement points The calculation formula is: （6） In the formula, The minimum pressure-bearing wall thickness of the device to be measured; Step 5.3: For each measurement point, calculate the absolute thinning amount (WT) and relative thinning amount for each measurement point. Total thinning rate and remaining lifespan The monitoring levels of each measurement point are classified. If the relative thinning at the measurement point ≤20% and total thinning rate ≤0.1mm / a and remaining life If the measurement period is ≥8 years, the monitoring level of the measurement point will be classified as Level C; if the measurement point meets the relative thinning requirement... >40% and total thinning rate >0.3mm / a and the absolute thinning amount WT>1mm, or the measurement point meets the remaining life requirement. If the monitoring period is less than 1.5 years, the monitoring level of the measurement point will be classified as Level A; except for the cases where the monitoring level is classified as Level A and Level C, the monitoring level of the measurement point will be classified as Level B in all other cases. Step 6: Based on the monitoring level of each measurement point, redetermine the thickness measurement frequency of each measurement point and update the thickness measurement log of each measurement point. Step 7: Use the fixed-point thickness measurement corrosion monitoring and processing center to retrieve and update the thickness measurement records of each measurement point, and push the thickness measurement records of measurement points with monitoring level A to the smart mobile terminal. Professional technicians can view the thickness measurement records of the measurement points on the smart mobile terminal, analyze each measurement point with monitoring level A, and formulate anti-corrosion measures.

2. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 1, if the device to be monitored is a refining and chemical equipment, the basic information obtained includes the individual equipment diagram and equipment ledger of the refining and chemical equipment; if the device to be monitored is a pipeline, the basic information obtained includes the single-line diagram and pipeline ledger of the pipeline.

3. The corrosion monitoring method based on fixed-point thickness measurement according to claim 2, characterized in that, The equipment ledger for the pipeline records the pipeline's number, name, starting point, ending point, material, internal flowing medium, design temperature, design pressure, operating temperature, operating pressure, pipeline length, number of welds, number of elbows, anti-corrosion and insulation materials, pressure rating, safety rating, equipment importance rating, commissioning time, maintenance records, and manufacturing unit.

4. The corrosion monitoring method based on fixed-point thickness measurement according to claim 2, characterized in that, When the refining equipment is a furnace, the equipment ledger records the furnace body name, process number, internal medium, equipment specifications, heat load, design pressure, design temperature, outlet pressure, outlet temperature, inlet pressure, inlet temperature, furnace tube material, furnace tube specifications, number of radiant furnace tubes, number of convection furnace tubes, elbow type, number of elbows, elbow material, highest temperature inside the furnace, flue temperature, number and model of burners, insulation method, equipment importance level, commissioning time, maintenance records, and manufacturing unit. When the refining equipment is a tower-type equipment, the equipment ledger records the tower's name, process number, specifications, material, tray structure parameters, tower top cover dimensions and material, tower bottom cover dimensions and material, tower top design temperature and design pressure, tower bottom design temperature and design pressure, tower top operating pressure and operating temperature, tower bottom operating pressure and operating temperature, equipment importance level, commissioning time, maintenance records, and manufacturing unit. When the refining equipment is a container-type equipment, the equipment ledger records the container's name, process number, storage medium, specifications, material, design temperature and design pressure, operating temperature and operating pressure, anti-corrosion and heat insulation materials, equipment importance level, commissioning time, maintenance records, and manufacturing unit. When the refining equipment is a heat exchanger, the equipment ledger records the name, model, process number, material, tube bundle and tube sheet dimensions, internal medium, tube side design pressure and design temperature, shell side design pressure and design temperature, tube side operating pressure and operating temperature, shell side operating pressure and operating temperature, vessel type, heat exchanger tube specifications and data, equipment importance level, commissioning time, maintenance records, and manufacturing unit. When the refining equipment is a reactor, the equipment ledger records the reactor's name, process number, model, volume, test pressure value, weight, internal medium, design temperature and design pressure, inlet temperature and outlet temperature, inlet pressure and outlet pressure, material, insulation material thickness, equipment importance level, commissioning time, maintenance records, and manufacturing unit.

5. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 2, each QR code corresponds to a device to be monitored. By scanning the QR code with a smart mobile terminal, the device ledger of the device to be monitored can be retrieved in real time, and the basic information of the device to be monitored can be obtained.

6. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 2, the QR code is attached to the surface of the device to be monitored by pasting, hanging, or inkjet printing.

7. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 3, the measurement points of the device to be monitored are selected according to the pipeline inspection layout requirements in SY / T 6553-2003, and the initial measurement frequency of the device to be monitored is set according to the pipeline inspection frequency in SY / T6553-2003.

8. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, The thickness measurement log includes the equipment name, drawing number, measurement point location number, diameter, wall thickness, material, internal medium, design temperature and design pressure, operating temperature and operating pressure, commissioning time, measurement time and measured wall thickness, and next measurement time for the device to be monitored.

9. A corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 4, the QR code on the device to be monitored is scanned using a barcode scanner on a smart mobile terminal to obtain the location information of the measurement point. Then, the wall thickness at the measurement point is measured using a thickness gauge, and the measured wall thickness is transmitted in real time to the fixed-point thickness measurement corrosion monitoring and processing center to realize the automatic association between the thickness measurement location and the thickness measurement information.

10. A corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 5.2, the first calculation coefficient of the total thinning rate is... Set to 0.75, the second calculation coefficient for total thinning rate. Set it to 0.

25.

11. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 5.2, if the device to be monitored is a pipeline, the minimum pressure-bearing wall thickness of the device to be monitored shall be determined according to the Petrochemical Pipeline Design and Equipment Selection Specification in SY / T 3059-2012; if the device to be monitored is a refining and chemical equipment, the minimum pressure-bearing wall thickness of the device to be monitored shall be determined according to GB150.3-2011.

12. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 5.2, when the device to be monitored is a pipe, and the pipe diameter is not less than 100mm and the wall thickness measured in the Nth time does not exceed 3mm, the remaining life of the pipe is directly determined to be 0 without calculation.

13. The corrosion monitoring method based on fixed-point thickness measurement according to claim 1, characterized in that, In step 6, if the monitoring level of the measurement point is A, the wall thickness of the measurement point is measured every 3 to 6 months; if the monitoring level of the measurement point is B, the wall thickness of the measurement point is measured every 6 months to 2 years; if the monitoring level of the measurement point is C, the wall thickness of the measurement point is measured every 4 years or in each operating cycle of the device to be monitored.

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