Oilfield station pipeline failure cause analysis system and method

Abstract

The oil field station pipeline failure cause analysis system and method, including sample collection module, environment information collection module, cause analysis module, damage mode identification module and output module; sample collection module connects cause analysis module, environment information collection module connects damage mode identification module; damage mode identification module and cause analysis module are connected to output module; through field data collection, failure mode identification, failure analysis sampling, failure analysis and other processes, the cause of the defect can be analyzed. When the oil field station pipeline failure problem is found, a theoretical guidance is provided to guide the on-site failure cause analysis, which can improve the on-site technical personnel's failure rapid ability.

Description

Technical Field

[0001] This invention belongs to the field of oilfield pipeline inspection technology, and specifically relates to a system and method for analyzing the causes of pipeline failures in oilfield stations. Background Technology

[0002] Existing patents related to pipeline defect detection and identification exist, and some standards specify pipeline failure modes. However, methods for determining the causes of pipeline failures, especially in oilfield pipelines, and the procedures for causal analysis are not clearly defined. Current methods for pipeline defect identification, detection, and the use of sensors and their packaging are not specifically designed for oilfield pipelines, and the specific causal analysis procedures, methods, and content are not defined. This prevents timely identification of the causes of pipeline failures when they are discovered in oilfield pipelines, hindering improvements and leading to the persistent presence of the same failure issues. Summary of the Invention

[0003] The purpose of this invention is to provide a system and method for analyzing the causes of pipeline failures in oilfield stations, in order to solve the problem that the failure causes cannot be improved, resulting in the same failure problem persisting for a long time.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] The oilfield pipeline failure cause analysis system includes a sample acquisition module, an environmental information acquisition module, a cause analysis module, a damage mode recognition module, and an output module. The sample acquisition module is connected to the cause analysis module, and the environmental information acquisition module is connected to the damage mode recognition module. Both the damage mode recognition module and the cause analysis module are connected to the output module.

[0006] The sample acquisition module is used for on-site sampling of defect locations; the environmental information acquisition module is used to acquire on-site environmental data and pipeline installation data.

[0007] The causation analysis module is used to analyze the morphology, mechanical properties, and chemical composition of the sample; the damage mode recognition module is used to classify damage modes based on 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 acquisition 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 based on the defective pipeline data and the defective equipment maintenance record.

[0010] Furthermore, defective pipeline data includes design data, construction data, and operational data; defective equipment maintenance records include inspection records, maintenance records, historical handling 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, location and depth of buried pipelines, and above-ground pipeline installation information.

[0012] Furthermore, the causal 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 bulk analysis, product analysis, and medium composition analysis; mechanical properties include tensile property testing, impact toughness testing, and hardness testing; and sample morphology analysis includes macroscopic morphology observation, metallographic structure observation, and SEM observation.

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

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

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

[0017] Collect on-site environmental data and pipeline installation data, classify damage modes, compare damaged pipelines with damage modes, determine the damage mode and send it 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 cause of damage defects in the damaged samples and send the results to the output module.

[0019] Further chemical analysis, mechanical property analysis, and sample morphology analysis are performed, including:

[0020] Digital cameras, stereomicroscopes, and 3D topography scanners were used to conduct macroscopic observations of on-site samples and to perform macroscopic measurements of defects.

[0021] For potential defects discovered during macroscopic inspection, non-destructive testing is performed to identify them, thus determining the specific location of the defects and guiding the specific sampling and analysis sites for failure analysis tests.

[0022] Microscopic analysis of the metallographic structure is performed under an electron microscope to analyze the precipitation of the second phase and the morphology of the structure. Defects are observed to determine their morphology and orientation, and the causes of defects are analyzed based on the metallographic observation results.

[0023] Metallographic analysis was performed on the cross-section of the sampled material to further determine the degree of pipe material deterioration, defect morphology, and material microstructure, and to analyze the causes of defects.

[0024] The hardness of the sampled surface and the upper and lower surfaces of the cross-section are tested along two lines respectively. The hardness values ​​at different locations are analyzed to evaluate whether the hardness meets the requirements.

[0025] The specimens are processed according to the tensile test method, and the tensile properties of the specimens are tested. The tensile specimens are made along the axial direction of the pipe, the tensile strength is tested, and the tensile fracture surface is observed.

[0026] The samples were processed into specimens according to the standards and then subjected to impact toughness tests.

[0027] Samples of defective pipes and devices were taken and chemical composition analysis was performed using a direct-reading spectrometer to confirm whether the materials met the relevant standard requirements.

[0028] The composition and elements of corrosion products are identified by scanning electron microscopy energy dispersive spectroscopy or XRD testing of corrosion product samples. For pipelines with microbial corrosion, bacterial solution samples are taken for analysis, and the types and contents of microorganisms are determined by microbial DNA testing and microbial culture methods.

[0029] For pipelines experiencing stress concentration, significant changes in geological environment, support failure, or deformation, stress analysis should be conducted to determine the relationships and stress state of the equipment.

[0030] For pipe sections or fittings with high water content, complex terrain, high flow velocity and pressure, complex medium composition, and obvious corrosion, conduct internal medium flow field simulation analysis to identify areas with relatively severe scouring and corrosion.

[0031] Furthermore, the damage modes are classified as follows: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, graphitization corrosion of cast iron, and fretting corrosion.

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

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

[0034] Based on the statistical data of pipeline failures at oilfield stations, we analyze the possible failure modes of pipelines and facilities at oilfield stations, and conduct failure mode analysis and corresponding cause analysis in accordance with standard failure mode identification and analysis methods.

[0035] Through processes such as on-site data collection, failure mode identification, failure analysis sampling, and failure analysis, this system can guide on-site personnel in conducting root cause analysis of defects. When pipeline failures are discovered at oilfield stations, it provides theoretical guidance on how to conduct on-site root cause analysis, and can enhance the rapid failure response capabilities of on-site technicians. Attached Figure Description

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

[0037] Figure 2 This is a flowchart of the present invention. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] In the description of this invention, it should be understood that the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

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

[0041] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Additionally, the character " / " in this invention generally indicates that the preceding and following objects have an "or" relationship.

[0042] It should be understood that although terms such as first, second, third, etc., may be used in the embodiments of the present invention to describe the preset range, these preset ranges should not be limited to these terms. These terms are only used to distinguish the preset ranges from one another. 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] Depending on the context, the word "if" as used here can be interpreted as "when," "when," "in response to determination," or "in response to detection." Similarly, depending on the context, the phrase "if determination" or "if detection (of the stated condition or event)" can be interpreted as "when determination," "in response to determination," "when detection (of the stated condition or event)," or "in response to detection (of the stated condition or event)."

[0044] The accompanying drawings illustrate various structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0045] The present invention will be further described below with reference to the accompanying drawings:

[0046] Please see Figures 1 to 2 This invention involves conducting causal analysis on defective pipelines discovered on-site. By collecting and analyzing on-site data and samples from the defective pipelines, the cause of the defect is determined, and targeted repair and maintenance measures are taken.

[0047] This research focuses on the causes of pipeline defects and failures in oilfields. It employs causal analysis, utilizing mechanical, chemical, and morphological methods, to analyze the root causes of pipeline failures. This provides theoretical guidance for eliminating inducing factors, repairing defects, and ensuring safe pipeline operation. Specific causal analysis is conducted on pipelines found to have defects in the field. Through on-site data collection and sampling analysis, the causes of defects are determined, and targeted maintenance measures are implemented. Based on statistical data on pipeline failures at oilfield sites, potential failure modes of pipelines and facilities are analyzed. Failure mode identification and analysis (FMEA) methods are used to conduct causal analysis and related work. The process of on-site data collection, failure mode identification, failure analysis sampling, and failure analysis guides on-site personnel in conducting causal analysis of defects.

[0048] Specifically:

[0049] The oilfield pipeline failure cause analysis system includes a sample acquisition module, an environmental information acquisition module, a cause analysis module, a damage mode recognition module, and an output module. The sample acquisition module is connected to the cause analysis module, and the environmental information acquisition module is connected to the damage mode recognition module. Both the damage mode recognition module and the cause analysis module are connected to the output module.

[0050] The sample acquisition module is used for on-site sampling of defect locations; the environmental information acquisition module is used to acquire on-site environmental data and pipeline installation data.

[0051] The causation analysis module is used to analyze the morphology, mechanical properties, and chemical composition of the sample; the damage mode recognition module is used to classify damage modes based on 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 acquisition 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 based on 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, location and depth of buried pipelines, and above-ground pipeline installation information.

[0055] The causal 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.

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

[0057] This invention establishes a method and process for analyzing the causes of pipeline failures in oilfield stations. For pipelines found to have defects in the field, specific work of cause analysis is carried out. Through methods such as on-site data collection and sampling analysis, the causes of the defects are determined, and targeted maintenance measures are taken. Based on statistical data of pipeline failures in oilfield stations, possible failure modes of pipelines and facilities are analyzed. Failure mode analysis is performed according to standard failure mode identification and analysis methods, and corresponding cause analysis is conducted.

[0058] Through processes such as on-site data collection, failure mode identification, failure analysis sampling, and failure analysis, this system can guide on-site personnel in conducting root cause analysis of defects. When pipeline failures are discovered at oilfield stations, it provides theoretical guidance on how to conduct on-site root cause analysis, and can enhance the rapid failure response capabilities of on-site technicians.

[0059] The module division in this embodiment of the invention is illustrative and represents only one logical functional division. In actual implementation, other division methods may be used. Furthermore, the functional modules in the various embodiments of the invention can be integrated into a single processor, exist as separate physical entities, or be integrated into a single module. The integrated modules described above can be implemented in hardware or as software functional modules.

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

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

[0062] Collect on-site environmental data and pipeline installation data, classify damage modes, compare damaged pipelines with damage modes, determine the damage mode and send it 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 cause of damage defects in the damaged samples and send the results to the output module.

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

[0065] Digital cameras, stereomicroscopes, and 3D topography scanners were used to conduct macroscopic observations of on-site samples and to perform macroscopic measurements of defects.

[0066] For potential defects discovered during macroscopic inspection, non-destructive testing is performed to identify them, thus determining the specific location of the defects and guiding the specific sampling and analysis sites for failure analysis tests.

[0067] Microscopic analysis of the metallographic structure is performed under an electron microscope to analyze the precipitation of the second phase and the morphology of the structure. Defects are observed to determine their morphology and orientation, and the causes of defects are analyzed based on the metallographic observation results.

[0068] Metallographic analysis was performed on the cross-section of the sampled material to further determine the degree of pipe material deterioration, defect morphology, and material microstructure, and to analyze the causes of defects.

[0069] The hardness of the sampled surface and the upper and lower surfaces of the cross-section are tested along two lines respectively. The hardness values ​​at different locations are analyzed to evaluate whether the hardness meets the requirements.

[0070] The specimens are processed according to the tensile test method, and the tensile properties of the specimens are tested. The tensile specimens are made along the axial direction of the pipe, the tensile strength is tested, and the tensile fracture surface is observed.

[0071] The samples were processed into specimens according to the standards and then subjected to impact toughness tests.

[0072] Samples of defective pipes and devices were taken and chemical composition analysis was performed using a direct-reading spectrometer to confirm whether the materials met the relevant standard requirements.

[0073] The composition and elements of corrosion products are identified by scanning electron microscopy energy dispersive spectroscopy or XRD testing of corrosion product samples. For pipelines with microbial corrosion, bacterial solution samples are taken for analysis, and the types and contents of microorganisms are determined by microbial DNA testing and microbial culture methods.

[0074] For pipelines experiencing stress concentration, significant changes in geological environment, support failure, or deformation, stress analysis should be conducted to determine the relationships and stress state of the equipment.

[0075] For pipe sections or fittings with high water content, complex terrain, high flow velocity and pressure, complex medium composition, and obvious corrosion, conduct internal medium flow field simulation analysis to identify areas with relatively severe scouring and corrosion.

[0076] Example:

[0077] Data and sample collection

[0078] (1) Data collection

[0079] The analysts first collected and analyzed the design, construction, and operational data of the defective pipeline, such as pipeline and equipment drawings, support and hanger types and performance indicators, operating pressure, temperature and fluctuations, and number of start-ups and shutdowns.

[0080] The inspection records, maintenance records, historical handling 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 treatment curves, design calculation instructions, design drawings, etc.) of defective equipment are collected and analyzed.

[0081] (2) On-site environmental analysis

[0082] A field investigation was conducted on the site environment of the defective pipelines and equipment, with a focus on factors such as ambient temperature, climate, soil corrosivity, environmental corrosivity, and geological conditions. Necessary detection methods were employed to determine the location and depth of buried pipelines, the installation status of above-ground pipelines, and the installation details of equipment, in order to assess the impact of environmental factors on the pipelines and equipment.

[0083] (3) Sample collection and determination

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

[0085] 2) Develop a plan for on-site sampling of defective areas based on the required testing and analysis methods to provide sufficient experimental samples for testing and analysis;

[0086] 3) Based on the actual site conditions and the user's failure cause analysis requirements, work with the operating unit to develop a final sampling plan, screen defective parts, and determine the final sampling method and quantity.

[0087] Failure Mode Classification

[0088] Failure mode analysis was conducted on oilfield pipelines and facilities. Based on the initial judgment of the macroscopic characteristics of the failed materials, and further confirmation of the causes of failure through experiments, the failure modes were mainly classified as follows:

[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, graphitization corrosion of cast iron, fretting corrosion).

[0094] Causal analysis methods

[0095] (1) Failure Analysis Methods

[0096] 1) Macro observation

[0097] Macroscopic observation of on-site samples is conducted to identify and macroscopically inspect surface defects. Digital cameras, stereo microscopes, and three-dimensional topography scanners can be used for macroscopic measurement of defects.

[0098] 2) Non-destructive testing

[0099] For potential defects discovered during macroscopic inspection, non-destructive testing is performed to identify their specific locations, guiding the sampling and analysis of specific areas in failure analysis tests. For welding defects such as incomplete penetration, inclusions, porosity, and insufficient weld metal, the causes can be analyzed based on the non-destructive testing results.

[0100] 3) Microscopic morphology analysis

[0101] Microscopic analysis of the metallographic structure under an electron microscope is performed to analyze the precipitation and morphology of the second phase. Defects (if any) are observed, their morphology and orientation are noted, and the causes of these defects are analyzed based on the metallographic observations. Energy dispersive spectroscopy (EDS) can be used to qualitatively determine the elemental composition of surface components and deposits, providing a basis for the composition of corrosion products and the causes of defects.

[0102] 4) Metallographic analysis

[0103] Metallographic analysis was performed on the cross-section of the sampled material to further determine the degree of material degradation, defect morphology, and material microstructure of the pipeline, and to analyze the causes of the defects.

[0104] 5) Material hardness analysis

[0105] Hardness was tested along two lines on the upper and lower surfaces of the sampling surface and cross-section, respectively. The hardness values ​​at different locations were analyzed to evaluate whether the hardness met the requirements.

[0106] 6) Tensile test

[0107] The specimens are prepared according to the tensile testing method, and their tensile properties are tested. The tensile specimens are prepared along the axial direction of the pipe, and the specimen dimensions should meet the relevant standard requirements. The test item is tensile strength, and the tensile fracture surface is observed.

[0108] 7) Impact test

[0109] According to the standard, the samples were processed into specimens and their impact toughness was tested to evaluate whether their fracture toughness met the requirements. Based on the material properties and operating conditions, the corresponding temperature for the Charpy impact test was selected, and laboratory experiments were conducted.

[0110] 8) Chemical composition analysis

[0111] Defective pipes and devices were sampled and subjected to chemical composition analysis using a direct-reading spectrometer, including analysis of elements such as C, Si, Mn, S, P, Cr, Ni, Mo, Nb, and Ti, to confirm whether the material met the relevant standard requirements. Before chemical composition analysis, the corrosion layer on the material surface was removed by grinding and ultrasonically cleaned with alcohol or acetone.

[0112] 9) Corrosion product analysis

[0113] By using scanning electron microscopy (SEM) energy dispersive spectroscopy (EDS) or XRD analysis of corrosion product samples, the composition and elements of corrosion products can be identified, thereby determining the cause of corrosion. For pipelines with microbial corrosion, bacterial culture samples can be analyzed, and the types and amounts of microorganisms can be determined through microbial DNA testing and microbial culture methods.

[0114] 10) Stress calculation and analysis

[0115] For pipelines exhibiting stress concentration, significant changes in geological environment, support failure, or deformation, stress analysis should be conducted to determine the relationships and stress state of the equipment, as well as the likelihood of stress-induced defects or failures and the causes of stress concentration.

[0116] 11) Flow field simulation calculation

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

[0118] Causal 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 occur under operating conditions and environment are judged, and the possible causes of defects are preliminarily determined.

[0121] 2) Macroscopic inspection and identification

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

[0123] 3) Failure test analysis

[0124] Based on the preliminary conclusions of the defect cause analysis, the causes of the defects were confirmed through experiments such as microscopic pipe material analysis, composition analysis, and mechanical analysis, providing a scientific basis for the cause analysis conclusions.

[0125] 4) Comprehensive Analysis

[0126] Based on the information provided by Party A and the relevant test analysis results, and considering the analysis results of medium flow and stress state, the causes and patterns of the defects were further determined, and the final confirmation of the causes of the defects was obtained. Furthermore, suggestions for improvement in subsequent maintenance, inspection, and monitoring were proposed.

[0127] All relevant content of each step involved in the aforementioned embodiments of the oilfield station pipeline failure cause analysis method can be referenced from the functional description of the corresponding functional module of the oilfield station pipeline failure cause analysis system in the embodiments of the present invention, and will not be repeated here.

[0128] The key points of the invention include the general principles, basic requirements, workflow, data collection work content, failure mode classification, and cause analysis work content of the oilfield station pipeline failure cause analysis method.

[0129] General Principles

[0130] This study investigates the causes of pipeline failures and their characteristics in oilfield pipelines, employing causal analysis techniques including mechanical, chemical, and morphological analysis. This analysis provides theoretical guidance for eliminating inducing factors, repairing defects, and ensuring safe pipeline operation.

[0131] The general provisions introduce the function of the patent, the basic requirements explain the necessary conditions for implementing the technical method, the workflow includes the working idea of ​​the whole 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, data collection, failure mode analysis, and cause analysis describe the implementation of the method in detail.

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

[0134] General principles → Basic requirements (determine if met, if met) → Workflow (including data collection → Failure mode analysis → Cause analysis)

[0135] Analysts should possess relevant knowledge of materials analysis and non-destructive testing, be clear about the various influencing factors of different types of defects, be familiar with relevant methods for analyzing the microstructure and properties of materials, have certain analytical experience, and have a thorough understanding of the materials, service conditions, and common causes of defects in industrial pipelines.

[0136] Based on statistical data of pipeline failures at oilfield sites, this study analyzes potential failure modes of pipelines and facilities at oilfield sites. Following standard failure mode identification and analysis methods, it conducts failure mode analysis and corresponding causal analysis. Through processes including on-site data collection, failure mode identification, failure analysis sampling, and failure analysis, the study guides on-site personnel in conducting causal analysis of defects.

[0137] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0138] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0139] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function 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 and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. An oilfield site pipeline failure cause analysis system, characterized by, The system comprises a sample collection module, an environment information collection module, a cause analysis module, a damage mode identification module and an output module; the sample collection module is connected to the cause analysis module, and the environment information collection module is connected to the damage mode identification module; the damage mode identification module and the cause analysis module are both connected to the output module; The sample collection module is used for sampling at a defect site; the environment information collection module is used for acquiring on-site environment data and pipeline installation data; The cause analysis module is used for sample morphology, mechanical property and chemical analysis; the damage mode identification module is used for dividing damage modes according to on-site environment data and pipeline installation data; The output module is used for outputting results of the cause analysis module and the damage mode identification module; The sample collection module comprises 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 samples on site according to defective pipeline data and defective equipment maintenance records; The defective pipeline data comprises design data, construction data and operation data; the defective equipment maintenance record comprises inspection records, maintenance records, manufacturing material quality certificates and welding process files in the manufacturing and installation process; The environment information collection module acquires on-site environment data and pipeline installation data, including environment temperature, climate, soil corrosiveness, environmental corrosiveness, geological conditions, buried pipeline position and burial depth, and aboveground pipeline installation information; The cause analysis module comprises a chemical analysis unit, a mechanical property analysis unit and a sample morphology analysis unit, which are respectively used for sample morphology, mechanical property and chemical analysis of the collected samples; Chemical analysis comprises material body analysis, product analysis and medium component analysis; mechanical property analysis comprises tensile property testing, impact toughness testing and hardness testing; sample morphology analysis comprises macroscopic morphology observation, metallographic structure observation and SEM observation; The damage modes divided by the damage mode identification module include corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

2. A method of failure cause analysis of oilfield site pipelines, characterized by, The oilfield station pipeline failure cause analysis system based on claim 1 comprises the following steps: Collect design data, construction data and operation data of a defective pipeline, and maintenance records of a defective equipment, determine a sampling scheme and sample on site; Collect on-site environment data and pipeline installation data, divide damage modes, match damaged pipelines and damage modes, determine damage modes of the damaged pipeline and send them to the output module; Perform chemical analysis, mechanical property analysis and sample morphology analysis on the samples taken on site, determine damage defect causes of the damaged samples and send them to the output module.

3. The oilfield facility piping failure cause analysis method of claim 2, wherein, Chemical analysis, mechanical property analysis and sample morphology analysis comprise: Use a digital camera, a stereo microscope and a three-dimensional morphology scanner to perform macroscopic observation on the samples taken on site, and perform macroscopic measurement of defects; Perform nondestructive testing and identification on potential defects found in the macroscopic inspection to determine specific positions of the defects and guide specific sampling and analysis positions of the failure analysis test; Microstructure is analyzed under electron microscope to observe the second phase precipitation and morphology of the microstructure, and the defects are observed to find out the causes of the defects; The cross section of the sample is analyzed to determine the deterioration degree of the pipe material, the defect morphology and the material structure, and the causes of the defects are analyzed; The hardness of the sample surface and the upper and lower surfaces of the cross section is tested along two lines to analyze the hardness values at different positions and to evaluate whether the hardness meets the requirements; The sample is processed according to the tensile test method, and the tensile property of the sample is tested; the tensile sample is taken along the axial direction of the pipe to test the tensile strength and observe the tensile fracture; The sample is processed according to the standard and the impact toughness test is carried out; The chemical analysis of the defect pipe sample is carried out by using the direct-reading spectrometer to confirm whether the material meets the requirements of the relevant standards; The composition and elements of the corrosion products are determined by the scanning electron microscope energy spectrum test or the XRD test of the corrosion product sample; the bacteria liquid sample of the pipe with microbial corrosion is analyzed; the type and content of the microorganisms are determined by the microbial DNA test and the microbial culture method; The stress analysis should be carried out for the pipe with stress concentration, obvious change of geological environment, support failure and deformation to determine the stress state of the pipe; The in-pipe medium flow field simulation analysis should be carried out for the pipe section or pipe fitting with high water content, complex terrain change, high flow velocity and pressure, complex medium composition and obvious corrosion to determine the relatively serious corrosion and erosion areas.

4. The oilfield facility piping failure cause analysis method of claim 2, wherein, The damage modes include: corrosion thinning, environmental cracking, mechanical damage, corrosion fatigue, cast iron graphitization corrosion and fretting corrosion.

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