Oil field station pipeline failure cause analysis system and method

Abstract

The invention discloses an oil field station pipeline failure cause analysis system and method. The system comprises a sample acquisition module, an environment information acquisition module, a cause analysis module, a damage mode recognition module and an output module, the sample acquisition module is connected with the cause analysis module; the environment information acquisition module is connected with the damage mode recognition module; the damage mode recognition module and the cause analysis module are both connected to the output module; through the processes of field data collection, failure mode recognition, failure analysis sampling, failure analysis and the like, field personnel can be guided to carry out defect cause analysis. When a pipeline failure problem of an oil field station pipeline is found, a theoretical guidance is provided to guide how to carry out onsite failure cause analysis, and rapid failure capability construction can be carried out for onsite technicians.

Description

Technical Field

[0001] The invention belongs to the technical field of oilfield pipeline detection, and in particular relates to a system and method for analyzing failure causes of pipelines at oilfield stations. Background Art

[0002] There are existing patents on pipeline defect detection and identification, and some standards have regulated the failure mode of pipelines, but the failure cause judgment method and cause analysis method process for pipelines, especially oilfield station pipelines, are not clear. The existing pipeline defect identification and determination methods, pipeline defect detection methods, sensors and sensor packaging methods are not targeted at oilfield station pipelines, and the specific cause analysis process, methods, and analysis content are not specified. When pipeline failure problems are found in oilfield station pipelines, the cause of failure cannot be obtained in time, so it is impossible to improve the cause of failure, resulting in the same failure problem existing for a long time. Summary of the invention

[0003] The purpose of the present invention is to provide an oilfield station pipeline failure cause analysis system and method to solve the problem that the failure cause cannot be improved, resulting in the long-term existence of the same failure problem.

[0004] To achieve the above object, the present invention adopts the following technical solutions:

[0005] The oilfield station pipeline failure cause analysis system includes a sample collection module, an environmental information collection module, a cause analysis module, a damage pattern recognition module and an output module; the sample collection module is connected to the cause analysis module, the environmental information collection module is connected to the damage pattern recognition module; the damage pattern recognition module and the cause analysis module are both connected to the output module;

[0006] The sample collection module is used for on-site sampling of defective parts; the environmental information collection module is used to obtain on-site environmental data and pipeline installation data;

[0007] The cause analysis module is used to analyze the sample morphology, mechanical properties and chemical composition; the damage pattern recognition module is used to divide the damage pattern according to the on-site environmental data and pipeline installation data;

[0008] The output module is used to output the results of the cause analysis module and the damage pattern recognition module.

[0009] Furthermore, the sample collection module includes a defective pipeline data storage unit, a defective equipment maintenance record unit and a sampling unit; the defective pipeline data storage unit, the defective equipment maintenance record unit and the sampling unit are connected in sequence, and the sampling unit performs on-site sampling according to the defective pipeline data and the defective equipment maintenance record.

[0010] Furthermore, defective pipeline data include design data, construction data and operation data; defective equipment maintenance records include inspection records, maintenance records, historical processing information, manufacturing material certificates, thermal processes during manufacturing, installation and maintenance, and welding process documents.

[0011] Furthermore, the environmental information acquisition module obtains on-site environmental data and pipeline installation data including: ambient temperature, climate, soil corrosivity, environmental corrosivity, geological conditions, buried pipeline location and depth, and above-ground pipeline installation information.

[0012] Furthermore, the cause analysis module includes a chemical analysis unit, a mechanical property analysis unit and a sample morphology analysis unit, which respectively analyze the sample morphology, mechanical properties and chemical composition of the collected samples.

[0013] Furthermore, the chemical analysis unit includes material analysis, product analysis and medium composition analysis; the mechanical properties include tensile properties test, impact toughness test and hardness test; the sample morphology analysis includes macroscopic morphology observation, metallographic structure observation and SEM observation.

[0014] Furthermore, the damage modes classified by the damage pattern recognition module include: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

[0015] Furthermore, the method for analyzing the causes of failure of pipelines at oilfield stations includes the following steps:

[0016] Collect design data, construction data and operation data of defective pipelines, as well as maintenance records of defective equipment, and determine the sampling plan for on-site sampling;

[0017] Collect on-site environmental data and pipeline installation data, classify damage patterns, compare damaged pipelines with damage patterns, determine damage patterns and send them to the output module;

[0018] The samples taken on site are subjected to chemical analysis, mechanical property analysis and sample morphology analysis to determine the causes of damage defects of the damaged samples and send them to the output module.

[0019] Further, chemical analysis, mechanical properties analysis and sample morphology analysis include:

[0020] Use digital cameras, stereo microscopes and 3D topography scanners to conduct macroscopic observation of on-site sampling and macroscopic measurement of defects;

[0021] For potential defects found in macroscopic inspection, non-destructive testing is carried out to identify the specific location of the defects and guide the specific sampling and analysis locations for failure analysis tests;

[0022] Conduct microscopic analysis of the metallographic structure under an electron microscope, analyze the precipitation of the second phase in the structure and the structure morphology, observe the defects found, observe the morphology and direction, and analyze the causes of the defects based on the metallographic observation results;

[0023] Conduct metallographic analysis on the cross section of the sampled material to further determine the degree of pipeline material deterioration, defect morphology and material structure, and analyze the causes of defects;

[0024] Test the hardness along two lines on the sampling surface and the upper and lower surfaces of the cross section, and analyze the hardness values ​​at different positions to evaluate whether the hardness meets the requirements;

[0025] The samples are processed according to the tensile test method and the tensile performance of the samples is tested; the tensile samples are prepared along the axial direction of the pipeline, the tensile strength is tested, and the tensile fracture is observed;

[0026] According to the standards, the samples are processed and the impact toughness is tested;

[0027] Take samples of defective pipelines and devices and use direct reading spectrometer to analyze the chemical composition to confirm whether the material meets the relevant standard requirements;

[0028] The components and elements of corrosion products are defined through scanning electron microscope energy spectrum test or XRD test of corrosion product sampling. For pipelines with microbial corrosion, bacterial liquid sampling and analysis are carried out, and the types and contents of microorganisms are determined through microbial DNA test and microbial culture method.

[0029] For pipelines with stress concentration, significant changes in geological environment, support failure, and deformation, stress analysis should be carried out to determine the relationship and stress state of the device;

[0030] For pipe sections or pipe fittings with high water content in the medium, complex terrain changes, high flow velocity and pressure, complex medium composition and obvious corrosion, a simulation analysis of the medium flow field in the pipe is carried out to determine the areas with relatively severe erosion and corrosion.

[0031] Furthermore, the damage modes are divided into: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

[0032] Compared with the prior art, the present invention has the following technical effects:

[0033] The present invention establishes a method and process for analyzing the causes of failure of pipelines in oilfield stations. For defective pipelines found on site, the specific work of cause analysis is carried out. By collecting on-site data of the defective pipelines, sampling and analyzing the same, the causes of the defects are determined, and targeted repair and maintenance measures are taken.

[0034] Based on the statistics of oilfield station pipeline failure data, the possible failure modes of oilfield station pipelines and facilities are analyzed. According to the standard failure mode identification and analysis methods, failure mode analysis is carried out and corresponding cause analysis work is carried out.

[0035] Through on-site data collection, failure mode identification, failure analysis sampling, failure analysis and other processes, on-site personnel can be guided to carry out defect cause analysis. When pipeline failure problems are found in oil field station pipelines, a theoretical guide is provided to guide how to carry out on-site failure cause analysis, which can build the rapid failure capacity of on-site technicians. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 This is a system structure diagram of the present invention.

[0037] Figure 2 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] In the description of the present invention, it should be understood that the terms “include” and “comprises” indicate the presence of described features, wholes, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or collections thereof.

[0040] It should also be understood that the terms used in the present specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention. As used in the present specification and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0041] It should be further understood that the term "and / or" used in the present specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes these combinations. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in the present invention generally indicates that the associated objects are in an "or" relationship.

[0042] It should be understood that, although the terms first, second, third, etc. may be used to describe preset ranges, etc. in the embodiments of the present invention, these preset ranges should not be limited to these terms. These terms are only used to distinguish preset ranges from each other. For example, without departing from the scope of the embodiments of the present invention, the first preset range may also be referred to as the second preset range, and similarly, the second preset range may also be referred to as the first preset range.

[0043] The word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrases "if it is determined" or "if (stated condition or event) is detected" may be interpreted as "when it is determined" or "in response to determining" or "when detecting (stated condition or event)" or "in response to detecting (stated condition or event)", depending on the context.

[0044] Various structural schematic diagrams of the embodiments disclosed in the present invention are shown in the accompanying drawings. These figures are not drawn to scale, and some details are magnified and some details may be omitted for the purpose of clear expression. The shapes of various regions and layers shown in the figures and the relative sizes and positional relationships therebetween are only exemplary, and may deviate in practice due to manufacturing tolerances or technical limitations, and those skilled in the art may additionally design regions / layers with different shapes, sizes, and relative positions according to actual needs.

[0045] The present invention is further described below in conjunction with the accompanying drawings:

[0046] See also Figure 1 to Figure 2 The present invention conducts specific work of cause analysis for defective pipelines found on site, determines the cause of the defect through on-site data collection, sampling and analysis of defective pipelines, and takes targeted repair and maintenance measures.

[0047] According to the defects and failure characteristics of oilfield pipelines, the cause analysis of the failure of pipelines is carried out. The cause analysis of the defects of failed pipelines is carried out through mechanical, chemical, morphological analysis and other means. Theoretical guidance is provided for the elimination of defect-inducing factors, defect repair and subsequent safe operation of pipelines. For defective pipelines found on site, specific cause analysis work is carried out. Through on-site data collection, sampling and analysis of defective pipelines, the causes of defects are determined, and targeted repair and maintenance measures are taken. According to the statistics of pipeline failure data of oilfield stations, the possible failure modes of pipelines and facilities in oilfield stations are analyzed, and failure mode analysis and corresponding cause analysis work are carried out according to standard failure mode identification and analysis methods. Through on-site data collection, failure mode identification, failure analysis sampling, failure analysis and other processes, on-site personnel can be guided to carry out cause analysis of defects.

[0048] Specific:

[0049] The oilfield station pipeline failure cause analysis system includes a sample collection module, an environmental information collection module, a cause analysis module, a damage pattern recognition module and an output module; the sample collection module is connected to the cause analysis module, the environmental information collection module is connected to the damage pattern recognition module; the damage pattern recognition module and the cause analysis module are both connected to the output module;

[0050] The sample collection module is used for on-site sampling of defective parts; the environmental information collection module is used to obtain on-site environmental data and pipeline installation data;

[0051] The cause analysis module is used to analyze the sample morphology, mechanical properties and chemical composition; the damage pattern recognition module is used to divide the damage pattern according to the on-site environmental data and pipeline installation data;

[0052] The output module is used to output the results of the cause analysis module and the damage pattern recognition module.

[0053] The sample collection module includes a defective pipeline data storage unit, a defective equipment maintenance record unit and a sampling unit; the defective pipeline data storage unit, the defective equipment maintenance record unit and the sampling unit are connected in sequence, and the sampling unit performs on-site sampling according to the defective pipeline data and the defective equipment maintenance record.

[0054] The environmental information acquisition module obtains on-site environmental data and pipeline installation data including: ambient temperature, climate, soil corrosivity, environmental corrosivity, geological conditions, buried pipeline location and depth, and above-ground pipeline installation information.

[0055] The cause analysis module includes a chemical analysis unit, a mechanical properties analysis unit and a sample morphology analysis unit, which analyze the sample morphology, mechanical properties and chemical composition of the collected samples respectively.

[0056] The damage modes classified by the damage pattern recognition module include: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

[0057] The present invention establishes a method and process for analyzing the causes of failure of pipelines in oilfield stations. For defective pipelines found on site, specific work of cause analysis is carried out. The causes of defects are determined by collecting on-site data of defective pipelines, sampling and analysis, etc., and targeted repair and maintenance measures are taken. Based on the statistics of failure data of pipelines in oilfield stations, possible failure modes of pipelines and facilities in oilfield stations are analyzed, and failure mode analysis and corresponding cause analysis are carried out based on standard failure mode identification and analysis methods.

[0058] Through on-site data collection, failure mode identification, failure analysis sampling, failure analysis and other processes, on-site personnel can be guided to carry out defect cause analysis. When pipeline failure problems are found in oil field station pipelines, a theoretical guide is provided to guide how to carry out on-site failure cause analysis, which can build the rapid failure capacity of on-site technicians.

[0059] The division of modules in the embodiments of the present invention is schematic and is only a logical function division. There may be other division methods in actual implementation. In addition, each functional module in each embodiment of the present invention may be integrated into one processor, or may exist physically separately, or two or more modules may be integrated into one module. The above-mentioned integrated modules may be implemented in the form of hardware or in the form of software functional modules.

[0060] Furthermore, based on the above system, the present invention proposes the following analysis method:

[0061] Collect design data, construction data and operation data of defective pipelines, as well as maintenance records of defective equipment, and determine the sampling plan for on-site sampling;

[0062] Collect on-site environmental data and pipeline installation data, classify damage patterns, compare damaged pipelines with damage patterns, determine damage patterns and send them to the output module;

[0063] The samples taken on site are subjected to chemical analysis, mechanical property analysis and sample morphology analysis to determine the causes of damage defects of the damaged samples and send them to the output module.

[0064] The chemical analysis, mechanical properties analysis and sample morphology analysis include:

[0065] Use digital cameras, stereo microscopes and 3D topography scanners to conduct macroscopic observation of on-site sampling and macroscopic measurement of defects;

[0066] For potential defects found in macroscopic inspection, non-destructive testing is carried out to identify the specific location of the defects and guide the specific sampling and analysis locations for failure analysis tests;

[0067] Conduct microscopic analysis of the metallographic structure under an electron microscope, analyze the precipitation of the second phase in the structure and the structure morphology, observe the defects found, observe the morphology and direction, and analyze the causes of the defects based on the metallographic observation results;

[0068] Conduct metallographic analysis on the cross section of the sampled material to further determine the degree of pipeline material deterioration, defect morphology and material structure, and analyze the causes of defects;

[0069] Test the hardness along two lines on the sampling surface and the upper and lower surfaces of the cross section, and analyze the hardness values ​​at different positions to evaluate whether the hardness meets the requirements;

[0070] The samples are processed according to the tensile test method and the tensile performance of the samples is tested; the tensile samples are prepared along the axial direction of the pipeline, the tensile strength is tested, and the tensile fracture is observed;

[0071] According to the standards, the samples are processed and the impact toughness is tested;

[0072] Take samples of defective pipelines and devices and use direct reading spectrometer to analyze the chemical composition to confirm whether the material meets the relevant standard requirements;

[0073] The components and elements of corrosion products are defined through scanning electron microscope energy spectrum test or XRD test of corrosion product sampling. For pipelines with microbial corrosion, bacterial liquid sampling and analysis are carried out, and the types and contents of microorganisms are determined through microbial DNA test and microbial culture method.

[0074] For pipelines with stress concentration, significant changes in geological environment, support failure, and deformation, stress analysis should be carried out to determine the relationship and stress state of the device;

[0075] For pipe sections or pipe fittings with high water content in the medium, complex terrain changes, high flow velocity and pressure, complex medium composition and obvious corrosion, a simulation analysis of the medium flow field in the pipe is carried out to determine the areas with relatively severe erosion and corrosion.

[0076] Example:

[0077] Data and sample collection

[0078] (1) Data Collection

[0079] The analysts first collected and analyzed the design data, construction data, and operation data of the defective pipeline, such as pipeline and device drawings, support and hanger types and performance indicators, operating pressure, temperature and fluctuations, and start and stop times.

[0080] The inspection records, maintenance records, historical processing information, manufacturing material certificates, thermal processes during manufacturing, installation and maintenance, and welding process documents (including welding material certificates, welding processes, welding parameters, post-weld processing curves, design calculation instructions, design drawings, etc.) of defective equipment are collected and analyzed.

[0081] (2) On-site environment analysis

[0082] Conduct field investigations on defective pipelines and device site environments, focusing on factors such as ambient temperature, climate, soil corrosivity, environmental corrosivity, geological conditions, etc. Take necessary detection measures to measure the location and depth of buried pipelines, installation conditions of ground pipelines, and device installation conditions to determine the impact of environmental factors on pipelines and devices.

[0083] (3) Sample collection and determination

[0084] 1) Based on the on-site data collection and macroscopic observation and analysis results, preliminarily determine the failure mode of the defective pipeline and determine the tests and analysis methods required for failure analysis;

[0085] 2) According to the test and analysis methods required, formulate corresponding methods to conduct on-site sampling plans for defective parts to provide sufficient experimental samples for test and analysis;

[0086] 3) Based on the actual situation on site and the failure cause analysis needs of the user unit, jointly formulate the final sampling plan with the operating unit, screen the defective parts and determine the final sampling method and quantity.

[0087] Failure mode classification

[0088] Failure mode analysis is carried out for oilfield pipelines and facility failure objects. Preliminary judgment is made based on the macroscopic characteristics of the failed materials. After further confirmation of the failure causes based on experiments, the failure modes are mainly divided into the following categories:

[0089] (1) Corrosion thinning (carbon dioxide corrosion, phenol corrosion, organic acid corrosion, atmospheric corrosion, soil corrosion, microbial corrosion, acidic water corrosion);

[0090] (2) Environmental cracking (chloride stress corrosion cracking, carbonate stress corrosion cracking, nitrate stress corrosion cracking, wet hydrogen sulfide damage, hydrogen embrittlement);

[0091] Material degradation (demetallization corrosion);

[0092] (3) Mechanical damage (mechanical fatigue, vibration fatigue, contact fatigue, mechanical wear, erosion, cavitation, overload);

[0093] (4) Other damage (corrosion fatigue, cast iron graphitization corrosion, fretting corrosion).

[0094] Causal analysis method

[0095] (1) Failure analysis method

[0096] 1) Macroscopic observation

[0097] For on-site sampling, macroscopic observation is carried out to identify and inspect surface defects. Digital cameras, stereo microscopes and 3D topography scanners can be used to perform macroscopic measurements of defects.

[0098] 2) Nondestructive testing

[0099] For potential defects found in macroscopic inspection, non-destructive testing is carried out to identify the specific location of the defects and guide the specific sampling and analysis parts of the failure analysis test. For welding defects such as incomplete penetration, inclusions, pores, and lack of welds that may exist in the weld, the causes can be analyzed based on the non-destructive testing results.

[0100] 3) Micromorphology analysis

[0101] Under the electron microscope, the metallographic structure is microscopically analyzed to analyze the precipitation of the second phase and the morphology of the structure, the defects found (if any), the morphology and direction are observed, and the causes of the defects are analyzed in combination with the metallographic observation results. The energy spectrum can be used to perform qualitative element determination and analysis on the surface composition, attachments, etc., to provide a basis for the composition of corrosion products, the causes of defects, etc.

[0102] 4) Metallographic analysis

[0103] Metallographic analysis is performed on the cross section of the sampled material to further determine the degree of pipeline material deterioration, defect morphology and material structure, and analyze the causes of the defects.

[0104] 5) Material hardness analysis

[0105] The hardness is tested along two lines on the sampling surface and the upper and lower surfaces of the cross section, and the hardness values ​​at different positions are analyzed to evaluate whether the hardness meets the requirements.

[0106] 6) Tensile test

[0107] The sample is processed according to the tensile test method and the tensile performance test is carried out on the sample. The tensile sample is prepared along the axial direction of the pipeline, and the sample size should meet the requirements of relevant standards. The test item is tensile strength, and the tensile fracture is observed.

[0108] 7) Impact test

[0109] According to the standard, the samples are processed and the impact toughness is tested to evaluate whether the fracture toughness meets the requirements. According to the material properties and operating process conditions, the corresponding temperature of the Charpy impact test is selected to carry out laboratory experiments.

[0110] 8) Chemical composition analysis

[0111] The samples of defective pipelines and devices are sampled and analyzed by direct reading spectrometer for chemical composition analysis, including analysis of elements such as C, Si, Mn, S, P, Cr, Ni, Mo, Nb, Ti, etc., to confirm whether the material meets the relevant standard requirements. Before the chemical composition analysis, the corrosion layer on the surface of the material is polished off and ultrasonically cleaned with alcohol or acetone.

[0112] 9) Corrosion product analysis

[0113] Through scanning electron microscope energy spectrum test or XRD test of corrosion product sampling, the composition and elements of corrosion products can be defined, so as to determine the cause of corrosion. For pipelines with microbial corrosion, bacterial liquid sampling and analysis can be carried out, and the type and content of microorganisms can be determined through microbial DNA testing and microbial culture methods.

[0114] 10) Stress calculation and analysis

[0115] For pipelines with stress concentration, significant changes in geological environment, support failure, deformation, etc., stress analysis should be carried out to determine the relationship and stress state of the device, the possibility of defects or failures caused by stress, and the causes of stress concentration.

[0116] 11) Flow field simulation calculation

[0117] For pipe sections or pipe fittings with high water content in the medium, complex terrain changes, high flow velocity and pressure, complex medium composition (containing sand, complex multiphase flow) and obvious corrosion, a simulation analysis of the medium flow field in the pipe should be carried out to determine the areas with relatively severe erosion and corrosion, so as to provide a basis for the causes of related defects.

[0118] Cause Analysis

[0119] 1) Data collection and analysis

[0120] Based on the results of on-site data collection and analysis, the types of defects and failure modes that may be caused by the operating conditions and environment are judged, and the possible causes of the defects are preliminarily determined.

[0121] 2) Macro inspection and identification

[0122] Based on the results of on-site macroscopic inspection and macroscopic observation and analysis in the sampling laboratory, the macroscopic characteristics of the defects are further clarified and corresponded with the defect morphology of the corresponding failure mode.

[0123] 3) Failure experiment analysis

[0124] According to the preliminary conclusions of the defect cause analysis, the causes of the defects are confirmed through micro-pipe material, component analysis, mechanical analysis and other test methods, providing a scientific basis for the conclusions of the cause analysis.

[0125] 4) Comprehensive analysis

[0126] Combined with the information provided by Party A and the results of relevant test analysis, the causes and patterns of defects are further determined based on the analysis results of medium flow and stress state, and the final confirmation of the causes of defects is obtained, and relevant improvement suggestions for subsequent maintenance, inspection and monitoring are put forward.

[0127] All relevant contents of each step involved in the aforementioned embodiment of the oilfield station pipeline failure cause analysis method can be referred to the functional description of the functional modules corresponding to the oilfield station pipeline failure cause analysis system in the embodiment of the present invention, and will not be repeated here.

[0128] The main points of the invention include the general principles, basic requirements, work flow, data collection work content, failure mode classification types and cause analysis work content of the oil field station pipeline failure cause analysis method.

[0129] General

[0130] According to the defects and failure characteristics of oilfield pipelines, the cause analysis of pipeline failure is carried out, and the cause analysis of the defects of failed pipelines is carried out through mechanical, chemical, morphological analysis and other means. The theoretical guidance is provided for the elimination of defect inducing factors, defect repair and subsequent safe operation of pipelines.

[0131] The general principles introduce the functions of the patent, the basic requirements explain the necessary conditions for the implementation of the technical method, the workflow contains the working ideas of the entire method, and the data collection, failure mode analysis, and cause analysis describe in detail the specific work and implementation content of each part of the workflow.

[0132] The general principles and basic requirements clearly define the scope of application of the method, and the workflow and data collection, failure mode analysis, and cause analysis describe the implementation of the method in detail.

[0133] Failure mode analysis can be implemented with reference to the same type of standards. Data collection is not limited to the content provided in the table. The experimental part of failure analysis can be implemented with reference to relevant experimental standards.

[0134] General Principles → Basic Requirements (Judge whether they are met, if so) → Workflow (including data collection → Failure Mode Analysis → Cause Analysis)

[0135] Analysts should have relevant knowledge of material analysis and non-destructive testing, understand the various influencing factors of various defects, be familiar with the methods of analyzing the structure and performance of relevant materials, have certain analysis experience, and have a full understanding of the materials, service conditions and causes of common defects of industrial pipelines.

[0136] Based on the statistics of pipeline failure data of oilfield stations, the possible failure modes of pipelines and facilities of oilfield stations are analyzed, and failure mode analysis and corresponding cause analysis are carried out according to the standard failure mode identification and analysis methods. Through the processes of on-site data collection, failure mode identification, failure analysis sampling, failure analysis, etc., on-site personnel can be guided to carry out cause analysis of defects.

[0137] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0138] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0139] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0140] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. Oilfield station pipeline failure cause analysis system, It is characterized in that It includes a sample collection module, an environmental information collection module, a cause analysis module, a damage pattern recognition module and an output module; the sample collection module is connected to the cause analysis module, the environmental information collection module is connected to the damage pattern recognition module; the damage pattern recognition module and the cause analysis module are both connected to the output module; The sample collection module is used for on-site sampling of defective parts; the environmental information collection module is used to obtain on-site environmental data and pipeline installation data; The cause analysis module is used to analyze the sample morphology, mechanical properties and chemical composition; the damage pattern recognition module is used to divide the damage pattern according to the on-site environmental data and pipeline installation data; The output module is used to output the results of the cause analysis module and the damage pattern recognition module.

2. The oilfield station pipeline failure cause analysis system according to claim 1, It is characterized in that The sample collection module includes a defective pipeline data storage unit, a defective equipment maintenance record unit and a sampling unit; the defective pipeline data storage unit, the defective equipment maintenance record unit and the sampling unit are connected in sequence, and the sampling unit performs on-site sampling according to the defective pipeline data and the defective equipment maintenance record.

3. The oilfield station pipeline failure cause analysis system according to claim 2, It is characterized in that Defective pipeline data include design data, construction data and operation data; defective equipment maintenance records include inspection records, maintenance records, historical processing information, manufacturing material certificates, thermal processes during manufacturing, installation and maintenance, and welding process documents.

4. The oilfield station pipeline failure cause analysis system according to claim 1, It is characterized in that The environmental information acquisition module obtains on-site environmental data and pipeline installation data including: ambient temperature, climate, soil corrosivity, environmental corrosivity, geological conditions, buried pipeline location and depth, and above-ground pipeline installation information.

5. The oilfield station pipeline failure cause analysis system according to claim 1, It is characterized in that The cause analysis module includes a chemical analysis unit, a mechanical properties analysis unit and a sample morphology analysis unit, which analyze the sample morphology, mechanical properties and chemical composition of the collected samples respectively.

6. The oilfield station pipeline failure cause analysis system according to claim 5, It is characterized in that The chemical analysis unit includes material analysis, product analysis and medium composition analysis; the mechanical properties include tensile properties test, impact toughness test and hardness test; the sample morphology analysis includes macroscopic morphology observation, metallographic structure observation and SEM observation.

7. The oilfield station pipeline failure cause analysis system according to claim 1, It is characterized in that The damage modes classified by the damage pattern recognition module include: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

8. Analysis method of causes of failure of pipelines in oilfield stations, It is characterized in that The oilfield station pipeline failure cause analysis system according to claims 1 to 7 comprises the following steps: Collect design data, construction data and operation data of defective pipelines, as well as maintenance records of defective equipment, and determine the sampling plan for on-site sampling; Collect on-site environmental data and pipeline installation data, classify damage patterns, compare damaged pipelines with damage patterns, determine damage patterns and send them to the output module; The samples taken on site are subjected to chemical analysis, mechanical property analysis and sample morphology analysis to determine the causes of damage defects of the damaged samples and send them to the output module.

9. The method for analyzing the causes of failure of pipelines in oilfield stations according to claim 8, It is characterized in that Chemical analysis, mechanical properties analysis and sample morphology analysis include: Use digital cameras, stereo microscopes and 3D topography scanners to conduct macroscopic observation of on-site sampling and macroscopic measurement of defects; For potential defects found in macroscopic inspection, non-destructive testing is carried out to identify the specific location of the defects and guide the specific sampling and analysis locations for failure analysis tests; Conduct microscopic analysis of the metallographic structure under an electron microscope, analyze the precipitation of the second phase in the structure and the structure morphology, observe the defects found, observe the morphology and direction, and analyze the causes of the defects based on the metallographic observation results; Conduct metallographic analysis on the cross section of the sampled material to further determine the degree of pipeline material deterioration, defect morphology and material structure, and analyze the causes of defects; Test the hardness along two lines on the sampling surface and the upper and lower surfaces of the cross section, and analyze the hardness values ​​at different positions to evaluate whether the hardness meets the requirements; The samples are processed according to the tensile test method and the tensile performance of the samples is tested; the tensile samples are prepared along the axial direction of the pipeline, the tensile strength is tested, and the tensile fracture is observed; According to the standards, the samples are processed and the impact toughness is tested; Take samples of defective pipelines and devices and use direct reading spectrometer to analyze the chemical composition to confirm whether the material meets the relevant standard requirements; The components and elements of corrosion products are defined through scanning electron microscope energy spectrum test or XRD test of corrosion product sampling. For pipelines with microbial corrosion, bacterial liquid sampling and analysis are carried out, and the types and contents of microorganisms are determined through microbial DNA test and microbial culture method. For pipelines with stress concentration, significant changes in geological environment, support failure, and deformation, stress analysis should be carried out to determine the relationship and stress state of the device; For pipe sections or pipe fittings with high water content in the medium, complex terrain changes, high flow velocity and pressure, complex medium composition and obvious corrosion, a simulation analysis of the medium flow field in the pipe is carried out to determine the areas with relatively severe erosion and corrosion.

10. The method for analyzing the causes of failure of pipelines in oilfield stations according to claim 8, It is characterized in that The damage modes classified include: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

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