Sulfur deposition thickness measuring system and method based on ultrasonic detection

Abstract

The invention provides a sulfur deposition thickness measuring system and method based on ultrasonic detection, the system comprises one or more ultrasonic probes, the multiple ultrasonic probes are respectively installed at different positions of an oil and gas transmission pipeline, the ultrasonic probes are used for transmitting ultrasonic signals to the oil and gas transmission pipeline at a certain frequency, and the ultrasonic signals are transmitted to the oil and gas transmission pipeline. Receiving an ultrasonic signal reflected back from a sulfur deposition layer of the oil and gas transmission pipeline; the system further comprises a data acquisition and processing device which is used for analyzing the ultrasonic signals and calculating the thickness of the sulfur deposition layer. The device can effectively eliminate the external interference, remarkably improves the measurement precision of the sulfur deposition thickness, has wide applicability, and is suitable for sulfur deposition detection on the surfaces of various metal materials.

Description

Technical Field

[0001] The present application relates to the technical field of ultrasonic nondestructive testing, and in particular to a sulfur deposition thickness measurement system and method based on ultrasonic testing. Background Art

[0002] In the process of oil and gas field development, the accuracy of sulfur deposition thickness detection in the transmission pipeline is crucial. This not only affects the assessment of equipment corrosion and maintenance needs, but also relates to the assessment of economic benefits and decision-making adjustments, and is of great significance to the formulation of oil production processes in oil and gas field development.

[0003] The thickness of sulfur deposits in oil pipelines directly affects the operating status and oil production efficiency of equipment, including the formulation of maintenance plans, the safety of equipment operation, and the optimization of production strategies. Accurate detection of sulfur deposits in pipelines can effectively prevent equipment failures and ensure production safety; in addition, adjusting the production process according to the sulfur deposition situation and selecting appropriate technical means can improve the recovery rate and reduce operating costs. Moreover, by monitoring the thickness of sulfur deposits, equipment that needs cleaning and maintenance can be identified in a timely manner, thereby reducing downtime and improving operating efficiency. If the thickness of sulfur deposits in pipelines is not accurately detected, it may lead to waste of resources, low production efficiency, and even equipment damage and safety accidents.

[0004] The main prediction methods for sulfur deposition thickness commonly used in ultrasonic detection include nuclear magnetic resonance-based detection and dust concentration prediction. For example, patent documents CN202410536171.X, a method for characterizing rock sulfur deposition damage rate and distinguishing sulfur deposition location based on nuclear magnetic resonance, and CN202110132164.X, a sulfur deposition test device for sulfur-containing natural gas gathering and transportation pipelines, show solutions. Among these methods, the nuclear magnetic resonance-based sulfur deposition thickness detection has the disadvantages of high cost, expensive equipment, complex operation, the need for professional personnel, high requirements for the detection environment, and cannot be used under high temperature and high pressure conditions; while dust concentration detection is indirect, and the sulfur deposition is inferred by measuring the dust concentration. The result may not be accurate enough, the sensitivity is low, and when the dust concentration is low or unevenly distributed, the detection effect may not be ideal. Summary of the invention

[0005] In view of this, the present application provides a sulfur deposition thickness measurement system and method based on ultrasonic detection. The solution has strong applicability, simple operation, and more accurate detection results.

[0006] To achieve the above objectives, the technical solutions adopted in this application are as follows:

[0007] In a first aspect, the present application provides a sulfur deposition thickness measurement system based on ultrasonic detection, comprising one or more ultrasonic probes, wherein the plurality of ultrasonic probes are respectively installed at different positions of an oil and gas transmission pipeline, and the ultrasonic probes are used to transmit ultrasonic signals to the oil and gas transmission pipeline at a certain frequency, and receive ultrasonic signals reflected back from the sulfur deposition layer of the oil and gas transmission pipeline;

[0008] The system also includes a data acquisition and processing device for analyzing the ultrasonic signal and calculating the thickness of the sulfur deposition.

[0009] Optionally, the sulfur deposition thickness measurement system further includes:

[0010] A three-dimensional reconstruction device is used to generate a three-dimensional thickness field (x, y, d) based on sulfur deposition thickness data at multiple angles using an interpolation algorithm and a least squares method, wherein x is used to characterize the lateral vector of the ultrasonic probe in the spatial position, y is used to characterize the longitudinal vector of the ultrasonic probe in the spatial position, and d is used to characterize the sulfur deposition thickness vector.

[0011] Optionally, the sulfur deposition thickness measurement system further includes an algorithm correction module, and the algorithm correction module further includes:

[0012] De-noising module, used to perform frequency domain analysis using wavelet transform and Fourier transform to filter out high-frequency noise in thickness detection results;

[0013] The multiple reflection correction module is used to calculate the correction factor of multiple reflections according to the propagation characteristics of the ultrasonic signal, and to correct the thickness of the sulfur deposition according to the correction factor.

[0014] Optionally, the sulfur deposition thickness measurement system further includes:

[0015] Automatic data analysis module, used to analyze the variation trend of sulfur deposition thickness over time using linear regression statistical method based on long-term stored test results;

[0016] The alarm module is used to automatically trigger the alarm function when the detected sulfur deposition thickness value reaches or exceeds the critical thickness value.

[0017] Optionally, the sulfur deposition thickness measurement system further includes:

[0018] Wireless data transmission module, used to transmit measurement data to remote devices or the cloud;

[0019] Display module, used to display the measurement results in real time.

[0020] In a second aspect, the present application provides a method for measuring sulfur deposition thickness based on ultrasonic detection, the method being applied to a system having one or more ultrasonic probes, the multiple ultrasonic probes being respectively installed at different positions of an oil and gas transmission pipeline, the method comprising:

[0021] a. The ultrasonic probe transmits ultrasonic signals to the oil and gas pipeline at a certain frequency;

[0022] b. The ultrasonic probe receives the ultrasonic signal reflected from the sulfur deposition layer of the oil and gas pipeline and sends it to the data acquisition and processing device;

[0023] c. The data acquisition and processing device collects and uses the reflected ultrasonic signal to calculate the thickness of sulfur deposition in the oil and gas pipeline. The specific calculation method is:

[0024] Assume that the propagation speed of ultrasound in the sulfur deposition layer is V sulfur , the propagation time is t reflection , the thickness of the sulfur deposition layer d sulfur The calculation formula is:

[0025]

[0026] Among them, t reflection is the time delay from transmission to reception of the reflected signal.

[0027] Optionally, the sulfur deposition thickness measurement method further includes:

[0028] q1. Using the sulfur deposition layer thickness data at multiple angles, the interpolation algorithm and the least squares method are used to generate a three-dimensional thickness field (x, y, d), where x is used to characterize the transverse vector of the ultrasonic probe in the spatial position, y is used to characterize the longitudinal vector of the ultrasonic probe in the spatial position, and d is used to characterize the sulfur deposition thickness vector, specifically:

[0029] Using cubic spline interpolation, for the one-dimensional case, the cubic spline interpolation function can be expressed as:

[0030]

[0031] Among them, Si(x) is the spline function of each interval, usually in the form of:

[0032] S i (x) = a i +b i (xx i )+c i (xx i ) 2 +d i (xx i )3

[0033] By setting boundary conditions and continuity conditions, the values ​​of ai, bi, ci, and di can be solved.

[0034] The least squares model is:

[0035] d(x,y)=A·x

[0036] Among them, d(x,y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is a vector containing coordinate information.

[0037] The goal of the least squares method is to minimize the following objective function:

[0038]

[0039] By constructing the Jacobian matrix J and performing minimization calculations, the optimal parameter estimate can be obtained;

[0040] For each (x, y) point, its corresponding d value can be calculated by interpolation, and finally a three-dimensional thickness field (x, y, d) is obtained.

[0041] Optionally, the sulfur deposition thickness measurement method further includes:

[0042] q2. Use wavelet transform and Fourier transform to perform frequency domain analysis to filter out high-frequency noise in thickness detection results.

[0043] Optionally, the sulfur deposition thickness measurement method further includes:

[0044] q3. Calculate the correction factor of multiple reflections according to the propagation characteristics of the ultrasonic signal, and correct the thickness of the sulfur deposition according to the correction factor;

[0045] The correction factor for multiple reflections is calculated, usually based on the geometry and medium properties, and is expressed as:

[0046]

[0047] Among them, R i is the influence degree of the i-th reflection, and n is the number of reflections.

[0048] Then, the thickness calculation is corrected and the correction factor K is introduced into the final thickness calculation formula to obtain the correction factor K.

[0049] Thickness after positive sulfur,corrected for:

[0050]

[0051] The beneficial effects of this application are:

[0052] Achieve high-precision measurement: By adopting advanced ultrasonic technology, combined with high-frequency signals and signal processing algorithms, the measurement accuracy of sulfur deposition thickness is significantly improved, overcoming the limitations of traditional methods in complex environments.

[0053] Improve adaptability: Design a detection system that can adapt to various environmental conditions and can work effectively in high temperature, high pressure and dust environments to ensure the reliability and effectiveness of the test results.

[0054] Simplify the operation process: By optimizing equipment design and automated control, the convenience of operation is improved, the professional requirements for operators are reduced, and the detection process is made more efficient and user-friendly.

[0055] Reduce maintenance costs: Reduce reliance on high-precision logging equipment, use ultrasonic detection technology to achieve economical and effective sediment thickness measurement, and reduce equipment maintenance and operating costs.

[0056] Improve data processing efficiency: Through real-time data collection and rapid processing, timely monitoring of sulfur deposition status can be achieved, helping to adjust production strategies in a timely manner and optimize production processes.

[0057] Reduce errors and trial and error costs: Accurate thickness measurement can avoid maintenance delays or excessive cleaning caused by misjudgment, reduce trial and error time and costs, and improve work efficiency.

[0058] Support scientific decision-making: Provide accurate sulfur deposition thickness data to provide a solid basis for production decisions in oil and gas fields, help management formulate more reasonable maintenance and production strategies, and improve overall economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0060] Figure 1 This is a schematic diagram of the principle structure of the sulfur deposition thickness measurement system based on ultrasonic detection in this application;

[0061] Figure 2 This is a structural block diagram of a sulfur deposition thickness measurement system based on ultrasonic detection in this application;

[0062] Figure 3 This is a structural block diagram of the algorithm correction module of this application;

[0063] Figure 4 This is a flow chart of a sulfur deposition thickness measurement method based on ultrasonic detection in this application;

[0064] Figure 5 This is a comparison chart of the sulfur deposition layer thickness before and after calibration by the algorithm correction module of this application. DETAILED DESCRIPTION

[0065] In order to make the purpose, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments.

[0066] This application utilizes the propagation characteristics of ultrasonic waves in the pipeline to achieve accurate measurement of the thickness of the sulfur deposition layer. General ultrasonic detection equipment is usually composed of an ultrasonic transmitter, a receiver and a control system.

[0067] A transmitter emits high-frequency sound waves. When the sound waves encounter sulfur deposits, they are reflected. The receiver receives the reflected waves and measures their return time, thereby calculating the thickness of the deposits.

[0068] It should be noted that in order to ensure the efficiency and stability of the ultrasonic detection system, the implementation environment should meet the following conditions:

[0069] Temperature range: -20℃ to 80℃ to adapt to different industrial environments.

[0070] Pressure range: 0 to 10MPa, ensuring the system works normally under high pressure conditions.

[0071] Corrosion protection: The equipment casing should be made of anti-corrosion materials to ensure durability in chemical environments.

[0072] The ultrasonic detection equipment in this application is an ultrasonic probe, such as Figure 1 and 2 As shown, in the first aspect, the present application provides a sulfur deposition thickness measurement system based on ultrasonic detection, comprising one or more ultrasonic probes 210, wherein the multiple ultrasonic probes 210 are respectively installed at different positions of the oil and gas transmission pipeline, and the ultrasonic probes are used to transmit ultrasonic signals to the oil and gas transmission pipeline at a certain frequency, and receive ultrasonic signals reflected back from the sulfur deposition layer of the oil and gas transmission pipeline.

[0073] Initial equipment installation

[0074] like Figure 1As shown, according to the structural characteristics of the equipment and the estimated area of ​​sulfur deposition, a suitable installation point is selected. For long-distance pipelines, it is recommended to install an ultrasonic probe 210 at a certain distance of 0.5m, and use a magnetic bracket or a bolt clamp to firmly install the ultrasonic probe 210 on the outer wall of the oil and gas pipeline. For high-temperature and high-pressure pipelines, a protective shell can be used to protect the ultrasonic probe 210 from the external environment.

[0075] The ultrasonic probe 210 generally includes an ultrasonic transmitting device and an ultrasonic receiving device, wherein the ultrasonic transmitting device includes:

[0076] 1) Piezoelectric crystal sensor: piezoelectric material lithium tantalate is used as the ultrasonic emission source, and the piezoelectric crystal is stimulated by electrical signals to generate high-frequency ultrasonic waves. The frequency range is 5MHz to 20MHz, and the frequency selection needs to be adjusted according to the thickness of sulfur deposits and the acoustic characteristics of the pipeline material.

[0077] 2) Driving circuit: used to provide high-voltage short pulse current to excite the piezoelectric crystal, ensuring that the transmitted ultrasonic signal has sufficient penetration. The peak voltage of the pulse current is 100V to 200V, and the pulse width is hundreds of nanoseconds to match the high-frequency signal of the ultrasonic wave.

[0078] The ultrasonic receiving device is used in conjunction with the transmitting device to receive the ultrasonic signal reflected from the sulfur deposition layer. Its specific components are as follows:

[0079] 1) Piezoelectric crystal receiver: Similar to the transmitter, the receiver uses highly sensitive lithium tantalate piezoelectric material to convert ultrasonic signals into electrical signals.

[0080] 2) Preamplifier: Since the received reflected signal is weak, the preamplifier is used to perform preliminary amplification on the received signal. The signal gain can reach 60dB to improve the signal-to-noise ratio.

[0081] 3) Bandpass filter: used to filter out noise in ultrasonic signals and retain only valid signals within the target frequency range to ensure measurement accuracy.

[0082] In one embodiment, an ultrasonic transmitter Olympus 38DL PLUS ultrasonic thickness gauge can be used to transmit a signal, and a pulse short-wave signal with a frequency of 1-5 MHz can be selected to avoid signal interference caused by continuous transmission. The transmitted pulse signal can be expressed as:

[0083] s(t)=A·sin(2πft)

[0084] Among them, A is the signal amplitude, f is the frequency, and t is the time.

[0085] The ultrasonic receiving device uses a quartz piezoelectric sensor to capture the signal reflected from the sulfur deposition layer. The ultrasonic receiver is Olympus V506. The signal is processed by the preamplifier Analog Devices AD620 to increase the signal strength and reduce noise interference.

[0086] The AD620 uses a differential amplifier configuration, which can effectively suppress common-mode noise. The input signal passes through two input terminals (positive and negative inputs), and the amplifier only amplifies the difference part of the signal and suppresses the common noise signal.

[0087] Gain setting, the gain of AD620 can be set by external resistors, the gain formula is:

[0088]

[0089] Where RG is the resistor connected between the amplifier pins. Choosing the right value of RG will achieve the desired gain, thereby amplifying the weak reflected signal to a manageable level.

[0090] Low noise characteristics, AD620 is designed with low input noise characteristics, which can reduce the noise generated by itself while amplifying the signal. This is especially important for the processing of weak signals, which can ensure the clarity and reliability of the signal.

[0091] High input impedance, the AD620 has a high input impedance of 2MΩ, which enables it to be directly connected to a sensor or probe without significantly affecting the output of the signal source. High input impedance helps reduce signal attenuation, thereby retaining more of the original signal characteristics.

[0092] Output signal processing, after gain processing, the output signal of AD620 is amplified to a level suitable for subsequent processing, and is usually output to an analog-to-digital converter (ADC) for digitization. The signal after gain has a higher amplitude, which is convenient for subsequent data analysis and processing.

[0093] The sulfur deposition thickness measurement system further includes a data acquisition and processing device 220 for analyzing ultrasonic signals and calculating the thickness of the sulfur deposition layer. The data acquisition and processing device 220 includes:

[0094] 1) High-speed ADC (analog-to-digital converter): used to convert analog ultrasonic signals into digital signals. The ADC sampling rate is not less than 50MHz to ensure that subtle changes in ultrasonic signals are captured.

[0095] 2) FPGA / DSP processing unit: used to quickly process the time delay and amplitude change of the reflected signal and calculate the sulfur deposition thickness. The FPGA (such as Xilinx Spartan-6) is responsible for high-speed parallel data processing, and the DSP is used to execute complex algorithms such as denoising, filtering and feature extraction of the reflected signal.

[0096] The specific calculation method of sulfur deposition layer is:

[0097] Assume that the propagation speed of ultrasound in the sulfur deposition layer is V sulfur , the propagation time is t reflection , the thickness of sulfur deposition d sulfur The calculation formula is:

[0098]

[0099] Among them, t reflection is the time delay from transmission to reception of the reflected signal.

[0100] This solution has the advantages of high precision, real-time dynamic monitoring and strong adaptability, providing important data support for equipment maintenance, effectively reducing failure rates and improving production efficiency.

[0101] Furthermore, the data acquisition and processing device 220 can also be used for signal amplitude analysis:

[0102] The amplitude of the reflected signal is analyzed and combined with the intensity attenuation of the reflected signal to verify the result of the time delay calculation. For example, the signal processing module Texas Instruments TMS320 series DSP can be selected for amplitude analysis, and the analysis formula is:

[0103]

[0104] Among them, A reflected is the received reflected signal amplitude, A incident is the transmitted signal amplitude, α is the attenuation coefficient of the sulfur layer, d sulfurd is the sulfur deposition thickness.

[0105] Optional, such as Figure 2 As shown, the sulfur deposition thickness measurement system also includes:

[0106] The three-dimensional reconstruction device 230 is used to generate a three-dimensional thickness field (x, y, d) based on the sulfur deposition thickness data at multiple angles using an interpolation algorithm and a least squares method, wherein x is used to characterize the lateral vector of the ultrasonic probe at the spatial position, y is used to characterize the longitudinal vector of the ultrasonic probe at the spatial position, and d is used to characterize the sulfur deposition thickness vector.

[0107] By collecting thickness data from multiple angles and combining the three-dimensional reconstruction algorithm, interpolation algorithm and least squares method, the system can generate a three-dimensional thickness distribution map of the sulfur deposition layer in the equipment, providing more comprehensive reference data for equipment maintenance personnel.

[0108] The specific steps are:

[0109] 1) Data collection and processing

[0110] The thickness data measured from different probes are recorded as (x i ,y i ,z i ,d i ), where (x i ,y i ,z i ) is the spatial coordinate of the probe, d i is the corresponding thickness value.

[0111] 2) Interpolation algorithm

[0112] To generate a continuous thickness field, cubic spline interpolation can be used.

[0113] Cubic spline interpolation:

[0114] For the one-dimensional case, the cubic spline interpolation function can be expressed as:

[0115]

[0116] Among them, S i (x) is a spline function for each interval, usually in the form of:

[0117] S i (x) = a i +b i (xx i )+c i (xx i ) 2 +d i (xx i ) 3

[0118] By setting boundary conditions and continuity conditions, the values ​​of ai, bi, ci, and di can be solved.

[0119] 3) Least Squares Method

[0120] When performing multidimensional data interpolation, the least squares method is usually used to fit the thickness field.

[0121] Least Squares Model:

[0122] Set the model to:

[0123] d(x,y)=A·x

[0124] Among them, d(x,y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is a vector containing coordinate information.

[0125] The goal of the least squares method is to minimize the following objective function:

[0126]

[0127] By constructing the Jacobian matrix J and performing minimization calculations, the optimal parameter estimation can be obtained.

[0128] 4) Integration and generation of thickness field

[0129] Combining the above interpolation and fitting results, a three-dimensional thickness field (x, y, d) can be generated. For each (x, y) point, its corresponding d value can be calculated by interpolation, and finally a three-dimensional distribution map of the sulfur deposition layer can be obtained.

[0130] Optionally, the sulfur deposition thickness measurement system further includes an algorithm correction module 240, such as Figure 3 As shown, the algorithm correction module 240 further includes:

[0131] A denoising module 241 is used to perform frequency domain analysis using wavelet transform and Fourier transform to filter out high-frequency noise in the thickness detection result;

[0132] 1 Wavelet transform

[0133] Signal decomposition: Use wavelet transform to decompose the original signal into sub-signals of different frequencies. Select the appropriate wavelet basis Daubechies wavelet and perform multi-layer decomposition.

[0134]

[0135] Among them, c jk is the wavelet coefficient, ψ jk (t) is the wavelet basis function.

[0136] Then, threshold processing is applied to the wavelet coefficients to remove coefficients below the set threshold to eliminate noise. Commonly used threshold methods include soft threshold and hard threshold.

[0137] Soft Thresholding:

[0138]

[0139] Hard Threshold:

[0140]

[0141] Signal reconstruction,The denoised coefficients are reconstructed into denoised signals through inverse wavelet transform.

[0142]

[0143] in, is the coefficient after denoising.

[0144] 2FFT (Fast Fourier Transform)

[0145] Frequency domain transformation, applies FFT to the above denoised signal to convert the signal from time domain to frequency domain.

[0146]

[0147] Where N is the signal length and x(n) is the time domain signal.

[0148] Filtering, applying a bandpass filter in the frequency domain to remove unwanted frequency components (such as high-frequency noise and low-frequency interference). The filtered frequency domain signal is converted back to the time domain through inverse FFT.

[0149]

[0150] The multiple reflection correction module 242 is used to calculate the correction factor of multiple reflections according to the propagation characteristics of the ultrasonic signal, and to correct the thickness of the sulfur deposition layer according to the correction factor.

[0151] An ultrasonic propagation model is established, the correction factor of multiple reflections is calculated, and the correction factor is introduced into the thickness calculation. The reflection number correction algorithm first establishes an ultrasonic propagation model, considering the reflection and propagation characteristics of the signal in different media. It is assumed that the ultrasonic signal will have multiple reflections during the propagation process.

[0152] Signal decomposition is performed by separating the main reflection signal from the multiple reflection signals through signal processing techniques (such as pulse compression).

[0153] The correction factor for multiple reflections is calculated, usually based on the geometry and medium properties, and is expressed as:

[0154]

[0155] Among them, R i is the influence degree of the i-th reflection, and n is the number of reflections.

[0156] Then, the thickness calculation is corrected and the correction factor is introduced into the final thickness calculation formula:

[0157]

[0158] In multiple reflection correction, the influence degree R iThe value of is usually determined by experimental data and a signal propagation model. For example, the intensity of the reflected signal can be obtained by analyzing sulfur deposits of different thicknesses, building a model that records the intensity decay of each reflection, and measuring it under different conditions. Experimental data can help define R i The empirical value of the parameter can be used to more accurately correct the influence of multiple reflections on the measurement results.

[0159] Specific examples are:

[0160] Select standard sulfur deposit samples of different thicknesses to ensure that their thickness range covers the expected application scenarios. Use ultrasonic equipment to measure under the same environmental conditions. Set up multiple transmitting and receiving units to ensure uniform coverage of the signal. Record the ultrasonic propagation time and reflected signal amplitude of each sample. It is recommended to repeat the measurement multiple times to improve data reliability.

[0161] The signal amplitude of each measurement was analyzed to calculate the reflection intensity and time delay at different thicknesses. The relationship between reflection intensity and thickness was established. The data was then fitted and the following polynomial regression analysis method was used to obtain R i Experience Value:

[0162] Polynomial regression formula: A reflected =a0+a1·d+a2·d 2 +…+a n ·d n Among them, A reflected is the reflected signal amplitude, d is the sulfur deposition thickness, a0, a1, …, a n are the polynomial coefficients and n is the order of the polynomial.

[0163] like Figure 5 As shown, the verification results of the sulfur deposition layer thickness are compared with the actual measurement results, and the model parameters are adjusted to optimize the correction effect of the reflection number.

[0164] Optionally, the sulfur deposition thickness measurement system further includes:

[0165] The automatic data analysis module 250 is used to analyze the variation trend of sulfur deposition thickness over time using a linear regression statistical method based on the long-term stored test results, specifically including:

[0166] 1.) Long-term data storage

[0167] Data acquisition: after each ultrasonic measurement, the system records the measurement results, including timestamp, sulfur deposition thickness d sulfur , device status and other information.

[0168] Data format, the measurement results are stored in a CSV structured format to ensure data readability and ease of subsequent analysis.

[0169] For storage media, choose cloud storage to ensure data security and long-term availability.

[0170] Data backup, perform data backup regularly to prevent data loss and damage.

[0171] 2) Automatic trend analysis

[0172] Automatically analyze long-term stored data to generate a trend curve of sulfur deposition thickness changes. Use linear regression analysis and linear regression statistical methods to analyze the trend of sulfur deposition thickness changes over time. By fitting a straight line, predict future thickness changes.

[0173] Thickness variation calculation, by calculating the thickness difference between each measurement, generates time series thickness variation data.

[0174] Visual display, using the graphical tool Matplotlib to generate a thickness change curve chart, which is convenient for maintenance personnel to view trends.

[0175] The alarm module 260 is used to automatically trigger an alarm function when the detected sulfur deposition thickness value reaches or exceeds a critical thickness value, specifically including:

[0176] Critical thickness setting: set the critical thickness value. Once the thickness reaches or exceeds this value, the system will automatically trigger the alarm function.

[0177] The alarm mechanism reminds maintenance personnel to handle the problem in a timely manner through email, SMS or system notification.

[0178] Through long-term data storage and automatic trend analysis, it is possible to effectively monitor changes in sulfur deposition, help maintenance personnel identify problems in a timely manner, reduce equipment failures and downtime, and improve production efficiency and safety.

[0179] Optionally, the sulfur deposition thickness measurement system further includes:

[0180] A wireless data transmission module 270, for transmitting measurement data to a remote device or the cloud;

[0181] Specifically, the LoRa communication module can be used to achieve medium and long distance data transmission. The transmission distance of the LoRa module can reach several kilometers and is suitable for complex industrial environments.

[0182] Furthermore, the measurement data is uploaded to the cloud via the wireless data transmission module 270, and the user can remotely access the data via a PC or mobile device to monitor the operation of the device in real time.

[0183] The display module 280 is used to display the measurement results in real time.

[0184] The display module 280 displays the measurement results in real time through a liquid crystal display (LCD) or a touch screen, and adjusts the measurement parameters through a control interface. Specifically, it may include:

[0185] 1) Transmitting frequency adjustment: Users can adjust the frequency of ultrasonic transmission according to the equipment material and sulfur deposition characteristics to obtain the best reflection effect.

[0186] 2) Measurement mode: Two modes are provided: single measurement and continuous measurement. Continuous measurement is used to dynamically monitor the changes in sulfur deposition, and single measurement is suitable for regular equipment inspection.

[0187] 3) Data recording and playback: The display module supports historical data query and playback functions, allowing users to trace past measurement results and analyze the changing trend of sulfur deposition.

[0188] The system of the present application can adapt to a variety of industrial environments and can work normally under high temperature, high pressure and corrosive environments. It is particularly suitable for long-term monitoring of oil, natural gas and chemical production lines. Through high-speed signal processing and multiple reflection correction algorithms, the system can achieve micron-level precision in the thickness measurement of sulfur deposits. The system of the present application supports continuous measurement and remote data transmission, so users can grasp the operating status of the equipment in real time, promptly discover sulfur deposition problems in the equipment, and avoid downtime for maintenance. Through multi-point measurement technology, the system can reconstruct the three-dimensional distribution of sulfur deposition inside the equipment, providing more comprehensive information for equipment maintenance.

[0189] Second, as Figure 4 As shown, the present application provides a sulfur deposition thickness measurement method based on ultrasonic detection, the method is applied to a system having one or more ultrasonic probes, the multiple ultrasonic probes are respectively installed at different positions of the oil and gas transmission pipeline, the sulfur deposition thickness measurement method includes:

[0190] S401. The ultrasonic probe transmits ultrasonic signals to the oil and gas pipeline at a certain frequency;

[0191] S402. The ultrasonic probe receives the ultrasonic signal reflected from the sulfur deposition layer of the oil and gas pipeline and sends it to the data acquisition and processing device;

[0192] S403. The data acquisition and processing device collects and uses the reflected ultrasonic signal to calculate the thickness of sulfur deposition in the oil and gas pipeline. The specific calculation method is:

[0193] Assume that the propagation speed of ultrasound in the sulfur deposition layer is V sulfur , the propagation time is t reflection , the thickness of sulfur deposition d sulfur The calculation formula is:

[0194]

[0195] Among them, t reflection is the time delay from transmission to reception of the reflected signal.

[0196] This solution has the advantages of high precision, real-time dynamic monitoring and strong adaptability, providing important data support for equipment maintenance, effectively reducing failure rates and improving production efficiency.

[0197] Optionally, the sulfur deposition thickness measurement method further includes:

[0198] q1. Using the sulfur deposition thickness data at multiple angles, the interpolation algorithm and the least squares method are used to generate a three-dimensional thickness field (x, y, d), where x is used to characterize the transverse vector of the ultrasonic probe in the spatial position, y is used to characterize the longitudinal vector of the ultrasonic probe in the spatial position, and d is used to characterize the sulfur deposition thickness vector, specifically:

[0199] Using cubic spline interpolation, for the one-dimensional case, the cubic spline interpolation function can be expressed as:

[0200]

[0201] Among them, S i (x) is a spline function for each interval, usually in the form of:

[0202] S i (x) = a i +b i (xx i )+c i (xx i ) 2 +d i (xx i ) 3

[0203] By setting boundary conditions and continuity conditions, we can solve a i 、b i 、c i , and d i The value of .

[0204] The least squares model is:

[0205] d(x,y)=A·x

[0206] Among them, d(x,y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is a vector containing coordinate information.

[0207] The goal of the least squares method is to minimize the following objective function:

[0208]

[0209] By constructing the Jacobian matrix J and performing minimization calculations, the optimal parameter estimate can be obtained;

[0210] For each (x, y) point, its corresponding d value can be calculated by interpolation, and finally a three-dimensional thickness field (x, y, d) is obtained.

[0211] By collecting thickness data from multiple angles and combining the three-dimensional reconstruction algorithm, interpolation algorithm and least squares method, the system can generate a three-dimensional thickness distribution map of the sulfur deposition layer in the equipment, providing more comprehensive reference data for equipment maintenance personnel.

[0212] Optionally, the sulfur deposition thickness measurement method further includes:

[0213] q2. Use wavelet transform and Fourier transform to perform frequency domain analysis to filter out high-frequency noise in thickness detection results.

[0214] 1 Wavelet transform

[0215] Signal decomposition: Use wavelet transform to decompose the original signal into sub-signals of different frequencies. Select the appropriate wavelet basis Daubechies wavelet and perform multi-layer decomposition.

[0216]

[0217] Among them, c jk is the wavelet coefficient, ψ jk (t) is the wavelet basis function.

[0218] Then, threshold processing is applied to the wavelet coefficients to remove coefficients below the set threshold to eliminate noise. Common thresholding methods include soft thresholding and hard thresholding.

[0219] Soft Thresholding:

[0220]

[0221] Hard Threshold:

[0222]

[0223] Signal reconstruction,The denoised coefficients are reconstructed into denoised signals through inverse wavelet transform.

[0224]

[0225] in, is the coefficient after denoising.

[0226] 2FFT (Fast Fourier Transform)

[0227] Frequency domain transformation, applies FFT to the above denoised signal to convert the signal from time domain to frequency domain.

[0228]

[0229] Where N is the signal length and x(n) is the time domain signal.

[0230] Filtering, applying a bandpass filter in the frequency domain to remove unwanted frequency components (such as high-frequency noise and low-frequency interference). The filtered frequency domain signal is converted back to the time domain through inverse FFT.

[0231]

[0232] Optionally, the sulfur deposition thickness measurement method further includes:

[0233] q3. Calculate the correction factor of multiple reflections according to the propagation characteristics of the ultrasonic signal, and correct the thickness of the sulfur deposition layer according to the correction factor, specifically:

[0234] An ultrasonic propagation model is established, the correction factor of multiple reflections is calculated, and the correction factor is introduced into the thickness calculation. The reflection number correction algorithm first establishes an ultrasonic propagation model, considering the reflection and propagation characteristics of the signal in different media. It is assumed that the ultrasonic signal will have multiple reflections during the propagation process.

[0235] Signal decomposition is performed by separating the main reflection signal from the multiple reflection signals through signal processing techniques (such as pulse compression).

[0236] The correction factor for multiple reflections is calculated, usually based on the geometry and medium properties, and is expressed as:

[0237]

[0238] Among them, Ri is the influence degree of the i-th reflection, and n is the number of reflections.

[0239] Then, the thickness calculation is corrected and the correction factor is introduced into the final thickness calculation formula:

[0240]

[0241] like Figure 5 As shown, the verification results of the sulfur deposition layer thickness are compared with the actual measurement results, and the model parameters are adjusted to optimize the correction effect of the reflection number.

[0242] The ultrasonic detection method for sulfur deposition thickness in this application has strong real-time performance, can quickly conduct on-site detection, and is suitable for dynamic monitoring. It has wide applicability and is applicable to a variety of materials and environmental conditions, and is not limited by temperature and pressure. It has the advantages of low cost, relatively cheap equipment, low maintenance costs, and suitability for a wide range of applications. Under the inadequacies of nuclear magnetic resonance and dust concentration detection methods, the ultrasonic detection method has become a more effective choice due to its real-time performance, wide applicability, and low cost, especially in complex oilfield environments, and can provide more accurate and reliable sulfur deposition thickness measurements.

[0243] Furthermore, before actually measuring the thickness of the ultrasonic sulfur deposition layer, the present application solution may also perform a calibration process, specifically including:

[0244] 1. Empty pipe calibration: When the equipment is not running, perform no-load measurement to obtain the sound velocity and basic echo data of the pipe material. In the empty pipe state, the emitted ultrasonic wave should be able to directly penetrate the pipe wall and generate a strong reflection signal.

[0245] 2. Standard sample calibration: Measurements are made on standard sulfur deposition samples to obtain the ultrasonic reflection characteristics of sulfur layers of different thicknesses and store them in the system as reference data for measurement.

[0246] Furthermore, in order to more comprehensively monitor the thickness distribution of the sulfur deposition layer, the present application scheme also supports the arrangement of multiple ultrasonic probes. Multiple ultrasonic probes are installed at different locations of the oil and gas pipeline at the same time to form a grid layout. Each probe independently transmits an ultrasonic signal and receives a reflected wave. By measuring the echo time, the thickness of the sulfur deposition layer at different locations is calculated.

[0247] Furthermore, the system of the present application can also realize functions such as automatic calibration, fault diagnosis and maintenance, specifically:

[0248] 1Automatic calibration function

[0249] 1) Regular benchmark measurements

[0250] The speed of sound changes under different temperature and pressure conditions, affecting the propagation speed of the ultrasonic signal. Therefore, regular benchmark measurements can help correct the speed of sound in a timely manner.

[0251] Reference sample preparation,During the initial setting of the system, a standard sulfur deposition sample with known,thickness is selected as the reference for calibration.

[0252] Timed measurement: the system is set to automatically perform benchmark measurements regularly every day and record the ultrasonic propagation time of the benchmark sample.

[0253] Data recording, the measurement results are compared with the known thickness, and the data of each calibration is recorded.

[0254] 2) Automatic correction of sound speed

[0255] Sound speed calculation:

[0256]

[0257] Among them, V calibrate is the calibrated sound velocity, d standard is the known standard thickness, t reflection is the measured reflection time.

[0258] Sound speed update: update the calculated sound speed value to the system parameters for use in subsequent measurements.

[0259] 3) Parameter drift correction

[0260] Signal processing parameter correction, based on benchmark measurement results, adjusts the parameters in the signal processing algorithm to ensure that it adapts to environmental changes or device aging.

[0261] Parameter update: Automatically update the signal processing parameters in the system through algorithms to maintain measurement consistency and accuracy.

[0262] 2 Fault diagnosis and maintenance

[0263] The system has a built-in self-diagnosis function that can detect the working status of the transmitter, receiver and signal processing unit. When a hardware failure is detected, the system will promptly alarm and give a fault prompt, making it convenient for maintenance personnel to check and replace parts.

[0264] In the embodiments provided in the present application, it should be understood that the disclosed systems and methods can be implemented in other ways. For example, the node embodiments described above are only schematic. For example, the division of the modules is only a logical function division. There may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another device, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0265] The modules described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0266] In addition, each functional module in the embodiment of the present application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of hardware plus software functional units.

[0267] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A sulfur deposition thickness measurement system based on ultrasonic detection, characterized in that: It comprises one or more ultrasonic probes, which are respectively installed at different positions of the oil and gas pipeline, and are used to transmit ultrasonic signals to the oil and gas pipeline at a certain frequency, and receive ultrasonic signals reflected from the sulfur deposition layer of the oil and gas pipeline; The system also includes a data acquisition and processing device for analyzing the ultrasonic signal and calculating the thickness of the sulfur deposition.

2. A sulfur deposition thickness measurement system based on ultrasonic detection as claimed in claim 1, characterized in that: The sulfur deposition thickness measurement system further comprises: A three-dimensional reconstruction device is used to generate a three-dimensional thickness field (x, y, d) based on sulfur deposition thickness data at multiple angles using an interpolation algorithm and a least squares method, wherein x is used to characterize the lateral vector of the ultrasonic probe in the spatial position, y is used to characterize the longitudinal vector of the ultrasonic probe in the spatial position, and d is used to characterize the sulfur deposition thickness vector.

3. A sulfur deposition thickness measurement system based on ultrasonic detection as claimed in claim 1 or 2, characterized in that: The sulfur deposition thickness measurement system further includes an algorithm correction module, and the algorithm correction module further includes: De-noising module, used to perform frequency domain analysis using wavelet transform and Fourier transform to filter out high-frequency noise in thickness detection results; The multiple reflection correction module is used to calculate the correction factor of multiple reflections according to the propagation characteristics of the ultrasonic signal, and to correct the thickness of the sulfur deposition layer according to the correction factor.

4. A sulfur deposition thickness measurement system based on ultrasonic detection as claimed in claim 3, characterized in that: The sulfur deposition thickness measurement system further comprises: Automatic data analysis module, used to analyze the variation trend of sulfur deposition thickness over time using linear regression statistical method based on long-term stored test results; The alarm module is used to automatically trigger the alarm function when the detected sulfur deposition thickness value reaches or exceeds the critical thickness value.

5. A sulfur deposition thickness measurement system based on ultrasonic detection as claimed in claim 4, characterized in that: The sulfur deposition thickness measurement system further comprises: Wireless data transmission module, used to transmit measurement data to remote devices or the cloud; Display module, used to display the measurement results in real time.

6. A method for measuring sulfur deposition thickness based on ultrasonic detection, characterized in that: The method is applied to a system having one or more ultrasonic probes, wherein the plurality of ultrasonic probes are respectively installed at different positions of an oil and gas transmission pipeline, and the method comprises: a. The ultrasonic probe transmits ultrasonic signals to the oil and gas pipeline at a certain frequency; b. The ultrasonic probe receives the ultrasonic signal reflected from the sulfur deposition layer of the oil and gas pipeline and sends it to the data acquisition and processing device; c. The data acquisition and processing device collects and uses the reflected ultrasonic signal to calculate the thickness of sulfur deposition in the oil and gas pipeline. The specific calculation method is: Assume that the propagation speed of ultrasound in the sulfur deposition layer is V sulfur , the propagation time is t reflection , the thickness of sulfur deposition d sulfur The calculation formula is: Among them, t reflection is the time delay from transmission to reception of the reflected signal.

7. A method for measuring sulfur deposition thickness based on ultrasonic detection as claimed in claim 6, characterized in that: The sulfur deposition thickness measurement method further comprises: q1. Using the sulfur deposition thickness data at multiple angles, the interpolation algorithm and the least squares method are used to generate a three-dimensional thickness field (x, y, d), where x is used to characterize the transverse vector of the ultrasonic probe in the spatial position, y is used to characterize the longitudinal vector of the ultrasonic probe in the spatial position, and d is used to characterize the sulfur deposition thickness vector, specifically: Using cubic spline interpolation, for the one-dimensional case, the cubic spline interpolation function can be expressed as: Among them, S i (x) is a spline function for each interval, usually in the form of: S i (x)=a i +b i (x-x i )+c i (x-x i ) 2 +d i (x-x i ) 3 By setting boundary conditions and continuity conditions, we can solve a i , b i 、c i , and d i The value of . The least squares model is: d(x,y)=A·x Among them, d(x,y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is a vector containing coordinate information. The goal of the least squares method is to minimize the following objective function: By constructing the Jacobian matrix J and performing minimization calculations, the optimal parameter estimation can be obtained; For each (x, y) point, its corresponding d value can be calculated by interpolation, and finally a three-dimensional thickness field (x, y, d) is obtained.

8. A method for measuring sulfur deposition thickness based on ultrasonic detection as claimed in claim 6 or 7, characterized in that: The sulfur deposition thickness measurement method further comprises: q2. Use wavelet transform and Fourier transform to perform frequency domain analysis to filter out high-frequency noise in thickness detection results.

9. A method for measuring sulfur deposition thickness based on ultrasonic detection as claimed in claim 6 or 7, characterized in that: The sulfur deposition thickness measurement method further comprises: q3. Calculate the correction factor of multiple reflections according to the propagation characteristics of the ultrasonic signal, and correct the thickness of the sulfur deposition according to the correction factor; The correction factor for multiple reflections is calculated, usually based on the geometry and medium properties, and is expressed as: Among them, Ri is the influence degree of the i-th reflection, and n is the number of reflections. Then the thickness calculation is corrected, and the correction factor K is introduced into the final thickness calculation formula to obtain the corrected thickness d sulfur,corrected for:

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