A pipeline leakage real-time monitoring and early warning device and early warning method

Abstract

The application discloses a pipeline leakage real-time monitoring and early warning device and method, and belongs to the field of pipeline leakage monitoring and early warning.The device comprises a control module, a power supply module, a communication module, a wall thickness monitoring module and a stress monitoring module.The power supply module is responsible for supplying power to the other four modules.The wall thickness monitoring module and the stress monitoring module are responsible for collecting wall thickness thinning and stress signal data of the monitored pipeline.The control module controls the wall thickness monitoring module and the stress monitoring module to process the collected signal data, analyzes the pipeline wall thickness and stress load conditions, and controls the communication module to send early warning information to designated communication equipment when the early warning condition is reached.The device and method have the advantages of real-time monitoring and early warning, low cost and high timeliness, and solve the problems of high installation and maintenance cost, high false alarm rate and poor timeliness of pipeline repair detection of the existing oil and gas pipeline leakage monitoring and early warning device.

Description

Technical Field

[0001] This invention belongs to the field of oil and gas pipeline leakage monitoring and early warning technology, specifically relating to a pipeline leakage real-time monitoring and early warning device and a pipeline leakage real-time monitoring and early warning method. Background Technology

[0002] In oil and gas field enterprises, pipeline transportation is the primary method of oil and gas transport. The total length of oil and gas pipelines in Changqing Oilfield exceeds 100,000 kilometers. With the increasing service life of these pipelines, and factors such as the complexity of the transported media and natural disasters, crude oil pipeline leaks occur frequently, easily causing serious safety and environmental accidents with severe social impact. To effectively reduce or prevent pipeline leaks, various oil and gas pipeline leak monitoring and early warning devices are installed at important pipeline locations. Most of these devices, such as flow differential methods, negative pressure wave methods, and acoustic methods, only trigger an alarm after a leak occurs. Devices that provide pre-leak warnings, such as fiber optic vibration methods and pipeline temperature measurement methods, have high installation and maintenance costs and a high false alarm rate. Early warnings through pipeline inspection and testing have poor timeliness and a high error rate. Summary of the Invention

[0003] The purpose of this invention is to provide a real-time monitoring and early warning device for pipeline leaks, which solves the problems of poor timeliness and high false alarm rate of existing pipeline leak monitoring and early warning systems.

[0004] The present invention also aims to provide a method for real-time monitoring and early warning of pipeline leaks.

[0005] The first technical solution adopted in this invention is: a real-time monitoring and early warning device for pipeline leakage, comprising five parts: a control module, a power supply module, a communication module, a wall thickness monitoring module, and a stress monitoring module; wherein the power supply module is responsible for supplying power to the other four modules; the wall thickness monitoring module and the stress monitoring module are responsible for collecting wall thickness reduction and stress signal data of the monitored pipeline; the control module controls the wall thickness monitoring module and the stress monitoring module to process the collected signal data, analyze the pipeline wall thickness and stress load, and if the conditions for early warning are met, control the communication module to send the early warning information to the designated communication device.

[0006] The invention is further characterized in that,

[0007] The control module circuit board consists of four parts: main control module, signal acquisition module, signal processing module, and signal transmission module. It adopts a modular, plug-in design. The control module is used to control the wall thickness monitoring module, stress monitoring module, and communication module to acquire and process wall thickness and stress signals.

[0008] The communication module uses the industrial-grade 4G module WH-LTE-7S4 as the main data transmission method of the system. The communication module is controlled by C language through the UART interface on the control module, and the network transparent transmission mode is adopted to realize point-to-point data transmission and reception.

[0009] The wall thickness monitoring module consists of a wall thickness circuit and a wall thickness probe. The wall thickness circuit can control multiple wall thickness probes and mainly consists of three parts: an ultrasonic excitation circuit, a signal receiving circuit, and a power supply circuit. The power supply circuit controls the ultrasonic excitation circuit to excite the ultrasonic probe to generate ultrasonic waves using a high-voltage narrow pulse method, and the signal receiving circuit collects the echoes.

[0010] The wall thickness probe is an ultrasonic probe.

[0011] The stress monitoring module consists of a stress circuit and a stress probe. The stress circuit mainly consists of three parts: an excitation circuit, a pickup circuit, and a power supply circuit. The power supply circuit controls the excitation circuit to transmit a 400-4500Hz excitation signal to the stress probe, and the pickup circuit is used to receive the resonance signal generated by the stress probe.

[0012] The stress probe is a vibrating wire sensor.

[0013] The second technical solution adopted in this invention is a method for real-time monitoring and early warning of pipeline leakage, the specific operation steps of which are as follows:

[0014] Step 1: Obtain the current pipe section thickness D through the wall thickness monitoring module, and then use the original thickness D0 of the current pipe section to obtain the wall thickness reduction percentage M of the measured pipe section, M = (D0 - D) / D0;

[0015] Step 2: Obtain the stress P of the current pipe section through the stress monitoring module, and then use the allowable stress P0 of the current pipe section to obtain the stress percentage N of the tested pipe section, N = P / P0, where P0 = K × Φ × σs, K is the design coefficient, with a value of 0.72, Φ is the weld coefficient, and σs is the minimum yield strength of the steel pipe / MPa.

[0016] Step 3: Calculate the pipeline risk warning value Q;

[0017] Warning value Q = Percentage of wall thickness reduction of the tested pipe section M × Wall thickness reduction failure factor K1 + Percentage of stress on the tested pipe section N × Stress failure factor K2 = M × K1 + N × K2, K1 + K2 = 1;

[0018] If M≥85%, or N≥85%, or Q≥85%, the pipeline is judged to be about to rupture.

[0019] If M≤60%, N≤60%, and Q≤60%, then the pipeline is considered to be operating normally.

[0020] In other cases, it is determined that there are potential hazards in the pipeline.

[0021] The beneficial effects of this invention are as follows: The real-time monitoring and early warning device for pipeline leakage of this invention addresses the problems of high installation and maintenance costs, high false alarm rate, and poor timeliness of early warning for pipeline inspection and testing of existing oil and gas pipeline leakage monitoring and early warning devices. It designs an early warning device with real-time monitoring and early warning functions. This monitoring and early warning device is low in cost and highly timely, and completely solves the problems of poor timeliness and high error rate of existing pipeline monitoring methods. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of a real-time monitoring and early warning device for pipeline leakage according to the present invention;

[0023] In the diagram, 1 is the control module; 2 is the power supply module; 3 is the communication module; 4 is the wall thickness circuit; 5 is the wall thickness probe; 6 is the stress circuit; 7 is the stress probe; and 8 is the monitored pipeline. Detailed Implementation

[0024] The present invention provides a real-time monitoring and early warning device for pipeline leaks, such as... Figure 1 As shown, it includes five parts: control module 1, power supply module 2, communication module 3, wall thickness monitoring module, and stress monitoring module. Among them, power supply module 2 is responsible for supplying power to the other four modules; the wall thickness monitoring module and stress monitoring module are responsible for collecting wall thickness reduction and stress signal data of the monitored pipeline 8; control module 1 controls the wall thickness monitoring module and stress monitoring module to process the collected signal data, analyze the pipeline wall thickness and stress load, and if the conditions for early warning are met, control communication module 3 to send the early warning information to the designated communication device.

[0025] The control module 1 circuit board consists of four parts: main control module, signal acquisition module, signal processing module, and signal transmission module. It adopts a modular, plug-in design. The control module 1 is used to control the wall thickness monitoring module, stress monitoring module, and communication module 3 to acquire and process wall thickness and stress signals.

[0026] The communication module 3 uses the industrial-grade 4G module WH-LTE-7S4 as the main data transmission method of the system. The communication module 3 is controlled by C language through the UART interface on the control module 1, and the network transparent transmission mode is adopted to realize point-to-point data transmission and reception.

[0027] The wall thickness monitoring module consists of a wall thickness circuit 4 and a wall thickness probe 5. The wall thickness circuit 4 can control multiple wall thickness probes 5 and mainly consists of three parts: an ultrasonic excitation circuit, a signal receiving circuit, and a power supply circuit. The power supply circuit controls the ultrasonic excitation circuit to use a high-voltage narrow pulse method to excite the ultrasonic probe to generate ultrasonic waves, and the signal receiving circuit collects the echoes.

[0028] The wall thickness probe 5 is an ultrasonic probe.

[0029] The stress monitoring module consists of a stress circuit 6 and a stress probe 7. The stress circuit 6 is mainly composed of three parts: an excitation circuit, a vibration pickup circuit, and a power supply circuit. The power supply circuit controls the excitation circuit to transmit a 400-4500Hz excitation signal to the stress probe 7, and the vibration pickup circuit is used to receive the resonance signal generated by the stress probe 7.

[0030] The stress probe 7 is a vibrating wire sensor.

[0031] The present invention provides a real-time monitoring and early warning method for pipeline leakage, the specific operation steps of which are as follows:

[0032] Step 1: Obtain the current pipe section thickness D through the wall thickness monitoring module, and then use the original thickness D0 of the current pipe section to obtain the wall thickness reduction percentage M of the measured pipe section, M = (D0 - D) / D0;

[0033] Step 2: Obtain the stress P of the current pipe section through the stress monitoring module, and then use the allowable stress P0 of the current pipe section to obtain the stress percentage N of the tested pipe section, N = P / P0, where P0 = K × Φ × σs, K is the design coefficient, with a value of 0.72, Φ is the weld coefficient, and σs is the minimum yield strength of the steel pipe / MPa.

[0034] Step 3: Calculate the pipeline risk warning value Q;

[0035] Warning value Q = Percentage of wall thickness reduction of the tested pipe section M × Wall thickness reduction failure factor K1 + Percentage of stress on the tested pipe section N × Stress failure factor K2 = M × K1 + N × K2, K1 + K2 = 1;

[0036] If M≥85%, or N≥85%, or Q≥85%, the pipeline is judged to be about to rupture.

[0037] If M≤60%, N≤60%, and Q≤60%, then the pipeline is considered to be operating normally.

[0038] In other cases, it is determined that there are potential hazards in the pipeline.

[0039] The present invention will be further described below with reference to specific embodiments.

[0040] Example 1: (Wall thickness monitoring only)

[0041] like Figure 1As shown, the device is buried 0.8 meters underground at a location with good signal near the pipeline being tested. The four sets of wall thickness probes connected to the device are installed at four positions on the pipeline, above, below, left, and right. The control module is set to collect data once a day. The control module automatically calculates the four sets of wall thickness data. If any one of the four sets of data is 60% < M < 85%, the control module sends a message to the pipeline manager indicating that the M value at that location indicates a potential hazard in the pipeline. If M ≥ 85%, the control module sends a message to the pipeline manager indicating that the M value at that location indicates an impending rupture in the pipeline.

[0042] Example 2: (Stress monitoring only)

[0043] like Figure 1 As shown, the device is buried 0.8 meters underground at a location with good signal near the pipeline being tested. The four sets of stress probes connected to the device are installed at four positions on the pipeline: top, bottom, left, and right. The control module is set to collect data once per minute. The control module automatically calculates the four sets of stress data. If any one of the four sets of data has a stress value of 60% < N < 85%, the system sends a message to the pipeline manager indicating that the pipeline has a potential hazard at that location. If N ≥ 85%, the system sends a message to the pipeline manager indicating that the pipeline is about to rupture at that location.

[0044] Example 3: (Including both wall thickness monitoring and stress monitoring, and monitoring the same location)

[0045] like Figure 1 As shown, in a location with good signal near the pipeline being tested, the device is buried 0.8 meters underground. The four sets of wall thickness probes and four sets of stress probes connected to the device are installed at four positions on the pipeline: top, bottom, left, and right. The control module is set to collect wall thickness data once a day and stress data once a minute. The control module automatically calculates the four sets of wall thickness data and four sets of stress data. If any one of the eight sets of data is 60% < M < 85%, or 60% < N < 85%, or 60% < Q < 85%, then the pipeline manager is notified that the M, N, or Q value at that location indicates a potential pipeline malfunction. If M ≥ 85%, or N ≥ 85%, or Q ≥ 85%, then the pipeline manager is notified that the M, N, or Q value at that location indicates an impending pipeline rupture.

[0046] Example 4: (Including both wall thickness monitoring and stress monitoring at different locations)

[0047] like Figure 1As shown, in a location with good signal near the pipeline being tested, the device is buried 0.8 meters underground. Four sets of wall thickness probes connected to the device are installed at four positions (up, down, left, and right) on one location of the pipeline being tested. Four sets of stress probes connected to the device are installed at four positions (up, down, left, and right) on another location of the pipeline being tested. The control module is set to collect wall thickness data once a day and stress data once a minute. The control module automatically calculates the four sets of wall thickness data and four sets of stress data. If any one of the eight sets of data is 60% < M < 85%, or 60% < N < 85%, or 60% < Q < 85%, then the pipeline manager is notified that the M, N, or Q value at that location indicates a potential pipeline malfunction. If M ≥ 85%, or N ≥ 85%, or Q ≥ 85%, then the pipeline manager is notified that the M, N, or Q value at that location indicates an impending pipeline rupture.

Claims

1. A method for real-time monitoring and early warning of pipeline leaks, characterized in that, A real-time monitoring and early warning device for pipeline leakage is adopted. The real-time monitoring and early warning device for pipeline leakage includes five parts: control module (1), power supply module (2), communication module (3), wall thickness monitoring module, and stress monitoring module. Among them, the power supply module (2) is responsible for supplying power to the other four modules; the wall thickness monitoring module and the stress monitoring module are responsible for collecting wall thickness reduction and stress signal data of the monitored pipeline (8); the control module (1) controls the wall thickness monitoring module and the stress monitoring module to process the collected signal data, analyze the pipeline wall thickness and stress load, and if the conditions for early warning are met, control the communication module (3) to send the early warning information to the designated communication device. The wall thickness monitoring module consists of a wall thickness circuit (4) and a wall thickness probe (5); the wall thickness circuit (4) can control multiple wall thickness probes (5), and is mainly composed of an ultrasonic excitation circuit, a signal receiving circuit and a power supply circuit; the power supply circuit controls the ultrasonic excitation circuit to use a high voltage narrow pulse to excite the ultrasonic probe to generate ultrasonic waves, and the signal receiving circuit collects the echoes; The wall thickness probe (5) is an ultrasonic probe; The stress monitoring module consists of a stress circuit (6) and a stress probe (7). The stress circuit (6) is mainly composed of an excitation circuit, a pickup circuit and a power supply circuit. The power supply circuit controls the excitation circuit to transmit a 400~4500Hz excitation signal to the stress probe (7). The pickup circuit is used to receive the resonance signal generated by the stress probe (7). The stress probe (7) is a vibrating wire sensor; The specific steps are as follows: Step 1: Obtain the current pipe section thickness D through the wall thickness monitoring module, and then use the original thickness D0 of the current pipe section to obtain the wall thickness reduction percentage M of the measured pipe section, M=(D0-D) / D0; Step 2: Obtain the stress P of the current pipe segment through the stress monitoring module, and then use the allowable stress P0 of the current pipe segment to obtain the stress percentage N of the tested pipe segment, N = P / P0. Where P0 = K × Φ × σs, K is the design coefficient, with a value of 0.72, Φ is the weld coefficient, and σs is the minimum yield strength of the steel pipe; Step 3: Calculate the pipeline risk warning value Q; Warning value Q = Percentage of wall thickness reduction of the tested pipe section M × Wall thickness reduction failure factor K1 + Percentage of stress on the tested pipe section N × Stress failure factor K2 = M × K1 + N × K2, K1 + K2 = 1; If M≥85%, or N≥85%, or Q≥85%, the pipeline is judged to be about to rupture. If M≤60%, N≤60%, and Q≤60%, then the pipeline is considered to be operating normally. In other cases, it is determined that there are potential hazards in the pipeline.

2. The method for real-time monitoring and early warning of pipeline leakage according to claim 1, characterized in that, The control module (1) circuit board includes four parts: main control module, signal collection module, signal processing module, and signal transmission module. It adopts a modular, plug-in design. The control module (1) is used to control the wall thickness monitoring module, stress monitoring module and communication module (3) to collect and process wall thickness and stress signals.

3. The method for real-time monitoring and early warning of pipeline leakage according to claim 1, characterized in that, The communication module (3) uses the industrial-grade 4G module WH-LTE-7S4 as the main data transmission method of the system. Through the UART interface on the control module (1), the communication module (3) is controlled by C language and the network transparent transmission mode is adopted to realize point-to-point data transmission and reception.

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