An intelligent pipeline corrosion monitoring and protection system

Abstract

The present invention relates to the field of corrosion monitoring technology, specifically to an intelligent pipeline corrosion monitoring and protection system. The system includes: a dynamic potential perturbation measurement module, a local micro-area scanning module, a corrosion rate calculation module, a corrosion risk distribution analysis module, and an environmental parameter compensation module. In the present invention, by measuring the reference potential on the pipeline surface and applying instantaneous perturbations, combined with current change differential operations, the corrosion process is dynamically tracked, the real-time response capability is improved, a microelectrode array is arranged to cover corrosion hotspots, precise measurement is achieved, spatial resolution is improved, the current response change rate is calculated, the corrosion current density is calculated based on the electrochemical properties of the material, the corrosion rate is dynamically predicted, the regional distribution is analyzed based on the corrosion rate changes, the accuracy of the corrosion risk assessment is optimized, environmental factors are monitored, perturbation parameters are adjusted, interference is compensated, and monitoring accuracy under different working conditions is ensured, ensuring data stability and optimizing protective measures.

Description

Technical Field

[0001] The present invention relates to the technical field of corrosion monitoring, and in particular to an intelligent pipeline corrosion monitoring and protection system. Background Art

[0002] The field of corrosion monitoring technology involves the detection, analysis, and evaluation of the corrosion behavior of metals and their alloys under various environmental conditions. This technical field mainly involves corrosion detection methods, corrosion data collection and analysis, and corrosion protection measures. Corrosion monitoring generally includes corrosion rate detection based on electrochemical measurements, wall thickness measurement based on ultrasonic waves, and material integrity assessment based on radiographic or electromagnetic technology. In combination with long-term monitoring data, it analyzes the degradation trend of materials under the influence of different environmental factors. This technical field is widely used in industries such as oil, natural gas, chemicals, shipbuilding, and marine engineering. By real-time monitoring of the corrosion status of key structures such as pipelines and equipment, it provides data support for the implementation of appropriate protective measures.

[0003] Among them, the intelligent pipeline corrosion monitoring and protection system refers to the use of multiple sensing methods to monitor the corrosion status of the pipeline in real time and take corresponding protective measures based on the results of data analysis. The system usually includes electrochemical corrosion sensors to measure parameters such as the potential and current density of the inner and outer walls of the pipeline, ultrasonic thickness sensors to continuously monitor the pipe wall thickness, and wireless data transmission technology to upload the detection data to the monitoring terminal. In addition, the system uses machine learning algorithms to analyze the collected data, predicting the development trend of corrosion through historical data modeling and pattern recognition, and automatically adjusts the cathodic protection system or intelligent coating to release preservatives based on the analysis results to slow the corrosion process.

[0004] Existing technologies rely on electrochemical sensors, ultrasonic thickness measurement, and X-ray or electromagnetic detection, but they struggle to provide corrosion data with high temporal and spatial resolution. Point-type electrochemical sensors struggle to accurately characterize the dynamic changes in corrosion hotspots, resulting in blind spots in local corrosion assessments. While ultrasonic thickness measurement can monitor changes in pipe wall thickness, it cannot directly reflect the corrosion rate, affecting the accuracy of trend predictions. X-ray and electromagnetic methods rely on periodic inspections and struggle to achieve continuous monitoring, leading to corrosion being discovered only after it has intensified, increasing maintenance risks. Existing monitoring methods don't adequately consider the impact of environmental factors and are typically corrected through long-term trend analysis. These methods struggle to cope with real-time measurement errors under complex working conditions, impacting data reliability and leading to delayed adjustments to protective measures, reducing the effectiveness of corrosion control. Summary of the Invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose an intelligent pipeline corrosion monitoring and protection system.

[0006] In order to achieve the above objectives, the present invention adopts the following technical solutions: An intelligent pipeline corrosion monitoring and protection system includes:

[0007] The dynamic potential disturbance measurement module obtains the reference potential of the pipeline surface, controls the potential source to apply instantaneous disturbance, adjusts the disturbance amplitude and records the current changes before and after the disturbance, and obtains the transient current change through differential operation;

[0008] The local micro-area scanning module arranges a microelectrode array based on the transient current variation, adjusts the microelectrode position to cover the hot spot, records the local current response, calculates the distribution gradient, and obtains the local corrosion rate distribution value;

[0009] The corrosion rate calculation module calculates the current response amplitude change rate based on the transient current change and the local corrosion rate distribution value, calculates the corrosion current density based on the electrochemical characteristics of the pipeline material, calculates the dynamic change of the corrosion rate, calculates the time series based on the change, adjusts the measurement rate increment, and obtains the dynamic change value of the corrosion rate;

[0010] The corrosion risk distribution analysis module calculates the corrosion rate change in the region based on the dynamic change value of the corrosion rate, analyzes the area where the local ratio exceeds the standard, adjusts the scanning step size, calculates the hot spot range gradient, and obtains the corrosion hot spot distribution parameters;

[0011] The environmental parameter compensation module calls the corrosion hotspot distribution parameters, monitors the temperature, pressure and flow rate of the pipeline operating environment, calculates the environmental impact, adjusts the disturbance amplitude and interval, and calculates and obtains the environmental parameter compensation correction value.

[0012] As a further solution of the present invention, the transient current change includes the disturbance amplitude, the current before the disturbance, and the current after the disturbance. The local corrosion rate distribution value is specifically the local current response and the distribution gradient. The dynamic change value of the corrosion rate includes the current response amplitude change rate, the corrosion current density, the dynamic change of the corrosion rate, and the measured rate increment. The corrosion hotspot distribution parameters specifically refer to the regional corrosion rate change, the local ratio exceeding the standard area, the scanning step, and the hotspot range gradient.

[0013] As a further solution of the present invention, the dynamic potential perturbation measurement module includes:

[0014] The reference potential acquisition submodule obtains the pipeline surface potential, calls the reference electrode outside the pipeline to detect the reference potential, filters the potential data at different time points, calculates the potential fluctuation range, and selects the measured value in the potential stability interval as the pipeline surface reference potential;

[0015] The disturbance potential applying submodule controls the potential source to output an instantaneous potential disturbance of a target amplitude based on the reference potential of the pipeline surface, adjusts the disturbance amplitude and records the current change on the pipeline surface after the disturbance, selects the disturbance data with stable current fluctuation value, and obtains the current change before and after the disturbance;

[0016] The transient current calculation submodule uses the formula:

[0017] ;

[0018] Obtain the transient current change trend in multiple time periods, calculate and establish the transient current change;

[0019] in, Represents the transient current change, Represents the first Current value at the moment, Represents the first Current value at the moment, Represents the number of time segments, represents the applied perturbation potential, represents the reference potential of the pipeline surface, Represents the equivalent resistance of the pipe surface.

[0020] As a further solution of the present invention, the local micro-area scanning module includes:

[0021] The microelectrode placement submodule places a microelectrode array based on the transient current variation, detects the distribution of the transient current variation, determines the area with the larger current variation, adjusts the microelectrode position to cover the hotspot, and generates a hotspot coverage placement state;

[0022] The current response recording submodule calls the hotspot coverage layout state, records the local current response, obtains transient current data at multiple microelectrode positions, calculates the current response gradient distribution, and generates a current gradient distribution value;

[0023] The local corrosion rate calculation submodule calculates the distribution gradient based on the current gradient distribution value, obtains the microelectrode spacing, transient current change and current gradient distribution value, performs gradient calculation and weighted summation, and uses the formula:

[0024] ;

[0025] Obtain the local corrosion rate distribution value;

[0026] in, represents the local corrosion rate distribution value, Representative The current change at each microelectrode position, Representative The distance between each microelectrode and the adjacent microelectrode, is the number of microelectrodes.

[0027] As a further solution of the present invention, the corrosion rate calculation module includes:

[0028] The current change analysis submodule collects the current response data on the pipeline surface based on the transient current change and the local corrosion rate distribution value, calculates the amplitude change rate of the current response per unit time, analyzes the change trend of the current response over time, and obtains the current response amplitude change rate;

[0029] The corrosion current density calculation submodule calls the current response amplitude change rate and combines the electrochemical characteristics of the pipeline material to calculate the charge transfer relationship in the local area during the corrosion process using the formula:

[0030] ;

[0031] The current density per unit area during the corrosion process is calculated to obtain the corrosion current density;

[0032] in, represents the corrosion current density, Represents the change in current response per unit time, Represents the area of the measurement area, represents the charge transfer coefficient, represents the measurement time;

[0033] The corrosion rate trend calculation submodule calls the corrosion current density, combines the polarization curve parameters of the material, calculates the dynamic change trend of the corrosion rate per unit time, adjusts the measurement rate increment, and obtains the dynamic change value of the corrosion rate.

[0034] As a further solution of the present invention, the corrosion risk distribution analysis module includes:

[0035] The corrosion rate distribution calculation submodule obtains corrosion rate data at multiple locations within the region based on the dynamic change value of the corrosion rate, calculates the corrosion rate change rate between adjacent locations, constructs a distribution matrix of corrosion rate changes in multiple regions, calculates the corrosion rate gradients at multiple points, and generates a corrosion rate gradient matrix;

[0036] The ratio exceeding standard region identification submodule calls the corrosion rate gradient matrix, calculates the local ratio of the corrosion rate change rate in multiple regions, sets a threshold, filters the regions where the ratio exceeds the standard, calculates the distribution characteristics, and obtains the distribution parameters of the exceeding standard regions;

[0037] The hotspot range gradient calculation submodule calls the distribution parameters of the exceeding area, adjusts the scanning step size, compares the corrosion rate change gradient of the local area, and uses the formula:

[0038] ;

[0039] Calculate and obtain the distribution parameters of corrosion hot spots;

[0040] in, represents the corrosion hotspot distribution parameter, Representative The corrosion rate gradient value at each location, Representative The scanning step length of the position, Representative The excess ratio of each region, Representative The difference in the gradient of the neighborhood corrosion rate of each region, Represents the total number of calculation points in the area.

[0041] As a further solution of the present invention, the environmental parameter compensation module includes:

[0042] The corrosion hotspot distribution calculation submodule calls the corrosion hotspot distribution parameters, analyzes the corrosion intensity change trend of the differentiated areas, obtains the corrosion hotspot distribution data, calculates the pipeline wall thickness change rate based on the distribution data, screens the corrosion exacerbation area, and calculates the corrosion growth rate data;

[0043] The operating environment monitoring submodule monitors the temperature, pressure and flow rate of the pipeline operating environment based on the corrosion growth rate data, collects the operating parameters of the corresponding time period, compares the variation range of the operating parameters, and calculates the temperature-flow rate synergistic impact factor using the formula:

[0044] ;

[0045] Calculate and obtain the temperature-flow rate synergistic impact factor data to obtain the environmental impact coefficient;

[0046] in, represents the temperature-flow rate synergistic influence factor, 、 are the maximum and minimum operating temperatures, 、 are the maximum and minimum values of the operating flow rate, is the average pressure during the time period, is the set of corrosion influence coefficients corresponding to the corrosion growth rate data, is the number of selected corrosion hotspot areas;

[0047] The disturbance amplitude adjustment submodule calls the environmental impact coefficient, analyzes the disturbance impact range, calculates the disturbance correction value according to the environmental impact coefficient, adjusts the disturbance amplitude, determines the disturbance adjustment interval, and calculates and obtains the environmental parameter compensation correction value.

[0048] As a further aspect of the present invention, the intelligent pipeline corrosion monitoring and protection system further includes a corrosion protection control module;

[0049] The corrosion protection control module intelligently adjusts the cathodic protection current or sacrificial anode configuration according to the corrosion hotspot distribution parameters and the dynamic change value of the corrosion rate, optimizes the corrosion protection measures, and dynamically adjusts the protection strategy to reduce the corrosion risk.

[0050] Compared with the prior art, the advantages and positive effects of the present invention are:

[0051] In the present invention, by measuring the reference potential of the pipeline surface and applying a transient disturbance, and combining the current changes before and after the disturbance to perform differential operations, it is possible to dynamically track the corrosion process, obtain the transient current change, and improve the real-time response capability of the corrosion state. The microelectrode array is laid out and the position is adjusted to cover the hotspot to achieve accurate measurement of local corrosion, improve spatial resolution, and make the identification of corrosion hotspots more accurate. The rate of change of the current response amplitude is calculated, and the corrosion current density is calculated in combination with the electrochemical characteristics of the material. The corrosion rate is dynamically calculated to ensure accurate prediction of the corrosion trend. The regional corrosion rate distribution is calculated based on the dynamic change of the corrosion rate, the local ratio exceeding the standard area is analyzed, and the scanning step size is adjusted to optimize the accuracy of the corrosion risk assessment. Monitor temperature, pressure, and flow rate, calculate environmental influencing factors, adjust the disturbance amplitude and interval, compensate for environmental interference, ensure monitoring accuracy under different working conditions, ensure data stability and timely adjustment of protective measures. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 is a system flow chart of the present invention;

[0053] Figure 2 This is a flow chart of the dynamic potential perturbation measurement module of the present invention;

[0054] Figure 3 This is a flow chart of the local micro-area scanning module of the present invention;

[0055] Figure 4 This is a flow chart of the corrosion rate calculation module of the present invention;

[0056] Figure 5 This is a flow chart of the corrosion risk distribution analysis module of the present invention;

[0057] Figure 6 This is a flow chart of the environmental parameter compensation module of the present invention. DETAILED DESCRIPTION

[0058] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0059] In the description of the present invention, it should be understood that the terms "length," "width," "up," "down," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," and the like, indicating positions or relationships, are based on the positions or relationships shown in the accompanying drawings and are intended only to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting the present invention. Furthermore, in the description of the present invention, "plurality" means two or more, unless otherwise expressly and specifically defined.

[0060] For example 1, please refer to Figure 1 ,An intelligent pipeline corrosion monitoring and protection system includes: a dynamic potential disturbance measurement module to obtain the reference potential of the pipeline surface, control the potential source to apply instantaneous disturbance, adjust the disturbance amplitude and record the current change before and after the disturbance, and obtain the transient current change through differential operation;

[0061] The local micro-area scanning module arranges the microelectrode array based on the transient current change, adjusts the microelectrode position to cover the hot spot, records the local current response, calculates the distribution gradient, and obtains the local corrosion rate distribution value;

[0062] The corrosion rate calculation module calculates the current response amplitude change rate based on the transient current change and the local corrosion rate distribution value, calculates the corrosion current density based on the electrochemical characteristics of the pipeline material, calculates the dynamic change of the corrosion rate, calculates the time series based on the change, adjusts the measurement rate increment, and obtains the dynamic change value of the corrosion rate;

[0063] The corrosion risk distribution analysis module calculates the corrosion rate change in the region based on the dynamic change value of the corrosion rate, analyzes the area where the local ratio exceeds the standard, adjusts the scanning step size, calculates the hotspot range gradient, and obtains the corrosion hotspot distribution parameters;

[0064] The environmental parameter compensation module calls the corrosion hotspot distribution parameters, monitors the temperature, pressure and flow rate of the pipeline operating environment, calculates the environmental impact, adjusts the disturbance amplitude and interval, and calculates the environmental parameter compensation correction value;

[0065] The corrosion protection control module intelligently adjusts the cathodic protection current or sacrificial anode configuration according to the corrosion hotspot distribution parameters and the dynamic change value of the corrosion rate, optimizes the corrosion protection measures, and dynamically adjusts the protection strategy to reduce the corrosion risk.

[0066] In the corrosion protection control module, it is first necessary to collect corrosion data on the surface of the pipeline or metal structure, including the distribution parameters of the corrosion hotspots and the dynamic change values of the corrosion rate. The data can be collected by electrochemical sensors. These sensors can be placed on the inner or outer wall of the pipeline and measure the corrosion rate based on the change in electrode potential. For example, the corrosion rate detected in a certain pipeline section is 0.05 mm / year, while that in another section is 0.15 mm / year. The detection data is transmitted to the central data processing unit via wireless communication or wired connection. The data processing unit compares the corrosion rate information with the historical corrosion data, screens out areas with large changes in corrosion rate (such as more than 30%), and marks them as potential corrosion hotspots. These data are then used to calculate the adjustment amount of cathodic protection current or the need for additional sacrificial anodes. Specifically, when the corrosion rate in a certain area is detected to increase by more than 40% compared with the baseline rate (such as 0.1 mm / year), the cathodic protection current of the area needs to be increased. The calculation of the current increase is based on Faraday's law, by calculating the required charge and converting it into a current output. For example, the new corrosion current density in a certain area is 50 μA / cm², then based on an area of 200 cm², the required total current is 10 mA, and the constant current source output of the cathodic protection system is adjusted to provide an additional 10 mA protection current. At the same time, for the sacrificial anode system, when the total current demand of the corrosion hotspot in a certain area exceeds the design capacity (such as the preset maximum protection current of 20 mA), it is necessary to increase the anode material. When calculating the replenishment amount, the anode consumption rate needs to be considered. For example, the current efficiency of a magnesium alloy sacrificial anode is 55%, and the actual current that can be provided is 11 mA / g. After calculation, the anode mass that needs to be increased can reach more than 1 g. The adjusted protection scheme is continuously monitored as environmental conditions change, and iteratively optimized through intelligent algorithms to ensure the dynamic adaptability of the cathodic protection current or anode configuration, ultimately reducing the corrosion risk.

[0067] The transient current change includes the disturbance amplitude, the current before the disturbance, and the current after the disturbance. The local corrosion rate distribution value specifically refers to the local current response and the distribution gradient. The dynamic change value of the corrosion rate includes the current response amplitude change rate, the corrosion current density, the dynamic change of the corrosion rate, and the measured rate increment. The corrosion hotspot distribution parameters specifically refer to the regional corrosion rate change, the local ratio exceeding the standard area, the scanning step length, and the hotspot range gradient. The environmental parameter compensation correction value includes the pipeline operating environment temperature, pressure, flow rate, environmental impact, disturbance amplitude, and disturbance interval.

[0068] See also Figure 2 , the dynamic potential perturbation measurement module includes:

[0069] The reference potential acquisition submodule obtains the pipeline surface potential, calls the reference electrode outside the pipeline to detect the reference potential, filters the potential data at different time points, calculates the potential fluctuation range, and selects the measured value in the potential stability interval as the pipeline surface reference potential;

[0070] First, by connecting an external reference electrode to the pipe surface, the potential values at multiple time points are detected and recorded to form a set of potential data sets that change over time. For example, if sampling is performed once per second, 60 potential values can be obtained in one minute. The data records are shown in Table 1 below:

[0071] Table 1 Pipeline surface potential data (unit: V)

[0072]

[0073] As shown in Table 1, the potential data collected initially have slight fluctuations. Next, we need to screen the differentiated time points, that is, calculate the potential change between adjacent data points. If the change exceeds the preset threshold (e.g. 0.02V), the measurement value at that time point is removed, otherwise it goes to the next step of screening. The calculation is as follows:

[0074] (reserve);

[0075] (elimination);

[0076] (reserve);

[0077] Finally, after removing abnormal data, the potential fluctuation range is calculated using the difference between the maximum and minimum values, as shown in The fluctuation range of the interval calculation is Then, by setting a fluctuation threshold, for example, 0.02V, the stable potential interval that meets this condition is screened out, and finally the mean of the potential data in this interval is selected as the pipeline surface reference potential. For example, the mean of 10 data points in the stable interval (-0.86V to -0.85V) is calculated:

[0078] ;

[0079] Finally, the pipeline surface reference potential is obtained ,The results show that the pipeline surface potential remains at around -0.855 V in the stable range, with a small fluctuation range.,It can be used as a reference potential when the subsequent disturbance potential is applied, to ensure the stability of the reference potential during the measurement process, and improve the accuracy of subsequent calculations.

[0080] The disturbance potential application submodule controls the potential source to output the instantaneous potential disturbance of the target amplitude based on the reference potential of the pipeline surface, adjusts the disturbance amplitude and records the current change on the pipeline surface after the disturbance, selects the disturbance data with stable current fluctuation value, and obtains the current change before and after the disturbance;

[0081] First, based on the reference potential calculated in the previous paragraph , applying a perturbation potential , setting the disturbance amplitude to 0.1V, the target disturbance potential is:

[0082] ;

[0083] The potential source applies the potential instantaneously and records the current change on the pipeline surface every 5ms. For example, the current change data before and after the disturbance are shown in Table 2 below:

[0084] Table 2 Current change data before and after disturbance (unit: mA)

[0085]

[0086] Compare the current before and after the disturbance and calculate the average change:

[0087] ;

[0088] Finally, the current change before and after the disturbance is obtained ,The results show that after applying the disturbance potential, the current change on the pipeline surface is relatively stable, which can be used to calculate the transient current characteristics and further analyze the pipeline potential-current response characteristics.

[0089] The transient current calculation submodule is based on the current change before and after the disturbance, using the formula:

[0090] ;

[0091] Obtain the transient current change trend in multiple time periods, calculate and establish the transient current change;

[0092] in, Represents the transient current change, Represents the first Current value at the moment, Represents the first Current value at the moment, Represents the number of time segments, represents the applied perturbation potential, represents the reference potential of the pipeline surface, Represents the equivalent resistance of the pipe surface.

[0093] Formula to calculate transient current change :

[0094] ;

[0095] Set the number of time segments , calculated according to Table 2 :

[0096] ;

[0097] Find the average:

[0098] ;

[0099] Assuming the equivalent resistance of the pipe surface , then the potential difference is calculated as:

[0100] ;

[0101] Finally, the transient current change is calculated:

[0102] ;

[0103] The results show that the transient current change is 2 mA, which is related to the reference potential disturbance amplitude and current response characteristics. It can be used to evaluate the pipeline corrosion status, electrode polarization behavior and potential response trend, and ensure the stability of the pipeline corrosion detection system under different disturbance conditions.

[0104] See also Figure 3 , the local micro-area scanning module includes:

[0105] The microelectrode placement submodule places the microelectrode array based on the transient current variation, detects the distribution of the transient current variation, determines the area with the largest current variation, adjusts the microelectrode position to cover the hotspot, and generates the hotspot coverage placement state;

[0106] First, the transient current data at different positions are extracted, and the current changes at multiple time points are compared to calculate the transient current increment at each microelectrode position. and The current change between , by setting the detection cycle , obtain the changing trend of each microelectrode at multiple time points, and then Sorting is performed to screen out the microelectrode positions whose changes are higher than the set threshold. The threshold can be set according to historical experimental data or the average current fluctuation rate. For example, the threshold is set to 1.5 times the mean of the total sample change to ensure that the selected area is the current hotspot. After the hotspot area is selected, the distribution of microelectrodes is adjusted and an encrypted layout is adopted, that is, the microelectrode density is increased around the hotspot area to reduce the distance between adjacent microelectrodes to improve the spatial resolution of data acquisition. Assuming that the initial microelectrode spacing is When the change in the hotspot area exceeds the set value, the microelectrode spacing in the area is reduced to , and redistribute the microelectrode array. After adjusting the layout state, a layout plan of microelectrode hotspot coverage is formed according to the optimized layout state, so as to ensure the effective coverage rate of the microelectrodes and obtain the final hotspot coverage layout state.

[0107] Table 3: Transient current changes at different microelectrode positions

[0108]

[0109] As shown in Table 3, the transient current changes at the microelectrode positions (2.0, 0.5) and (2.5, 0.5) are the highest. Therefore, it is necessary to increase the microelectrode density at these positions, reduce the spacing to 0.5 mm, and rearrange the microelectrode array to improve the detection accuracy and obtain the final hotspot coverage layout state.

[0110] The current response recording submodule calls the hotspot overlay layout state, records the local current response, obtains the transient current data at the multi-microelectrode position, calculates the current response gradient distribution, and generates the current gradient distribution value;

[0111] Based on the optimized microelectrode array, the transient current changes at each microelectrode position are continuously recorded. Get the current value of all microelectrodes , and calculate the current difference between adjacent time points, that is, At the same time, in order to quantify the local current gradient change, the current data at adjacent microelectrode positions are calculated as follows: ,in and is the microelectrode spacing. For example, if the spacing of the hot spot area in the aforementioned layout scheme is set to 0.5 mm, this spacing is used for gradient calculation. Subsequently, a current gradient threshold is set for the calculated current gradient value. For example, when the gradient value is greater than 1.8 times the set mean, the area is marked as an area with drastic current changes, and the microelectrode current data of the area is extracted for subsequent calculations. This ensures the accuracy of the current data acquisition in the hot spot area and ultimately generates the current gradient distribution value.

[0112] Table 4: Transient current data at microelectrode locations

[0113]

[0114] As shown in Table 4, the current gradient at the microelectrode position (2.5, 0.5) is the highest, which is 5.5 μA / mm. This area is marked as a drastic change area. When the local corrosion rate is calculated subsequently, the weight of this area will be increased to ensure the calculation accuracy.

[0115] The local corrosion rate calculation submodule calculates the distribution gradient based on the current gradient distribution value, obtains the microelectrode spacing, transient current change and current gradient distribution value, and performs gradient calculation and weighted summation using the formula:

[0116] ;

[0117] Obtain the local corrosion rate distribution value;

[0118] in, represents the local corrosion rate distribution value, Representative The current change at each microelectrode position, Representative The distance between each microelectrode and the adjacent microelectrode, is the number of microelectrodes.

[0119] First, calculate the gradient distribution value of each microelectrode and obtain the microelectrode spacing and transient current changes , calculate the local corrosion rate by weighted summation, and set the formula:

[0120] ;

[0121] Among them, take , using the values in Table 2 and Perform the calculation:

[0122] ;

[0123] Finally, the local corrosion rate distribution value is obtained This value reflects the local corrosion rate. A higher value indicates that the corrosion rate in this area is faster. The microelectrode spacing can be further optimized to improve the detection accuracy.

[0124] See also Figure 4 , the corrosion rate calculation module includes:

[0125] The current change analysis submodule collects the current response data on the pipeline surface based on the transient current change and the local corrosion rate distribution value, calculates the amplitude change rate of the current response per unit time, analyzes the change trend of the current response over time, and obtains the current response amplitude change rate;

[0126] First, the current response data of the pipeline surface is collected. This process usually uses high-precision sensors such as electrochemical noise sensors or constant potentiostats to obtain transient current signals through multiple measurement points distributed on the pipeline surface. Subsequently, the collected data is normalized to eliminate external interference signals. The normalization calculation process can adopt the mean normalization method, that is, for a certain moment The transient current , the normalized calculation formula is ,in and The normalized data are further filtered, and the noise can be removed by sliding average filtering or wavelet transform. Based on the filtered data, the amplitude change rate of the current response per unit time is calculated. This calculation involves the difference operation of the current signals at adjacent time points, that is, for two consecutive time points and , the current response change is calculated as , at known time increments In the case of, the rate of change of the current response amplitude per unit time can be calculated using the formula ,in is the current change rate, all measurement points After the calculation is completed, the mean To express the overall current change trend, The number of measurement points is then measured, and the time trend of the current response is fitted using a trend fitting method, such as polynomial fitting or exponential smoothing method, to obtain the time evolution law of the current response amplitude change rate.

[0127] The corrosion current density calculation submodule uses the current response amplitude change rate and combines it with the electrochemical characteristics of the pipeline material to calculate the charge transfer relationship in the local area during the corrosion process using the formula:

[0128] ;

[0129] The current density per unit area during the corrosion process is calculated to obtain the corrosion current density;

[0130] in, represents the corrosion current density, Represents the change in current response per unit time, Represents the area of the measurement area, represents the charge transfer coefficient, represents the measurement time;

[0131] First, it is necessary to obtain the electrochemical characteristic parameters of the pipeline material, including the exchange current density of the material , Tafel slope and the redox potential of the metal These parameters are usually obtained through experimental measurements, such as electrochemical impedance spectroscopy (EIS) or Tafel plot determination, and then the rate of change of the current response amplitude is measured. Calculate the amount of charge transferred per unit time. This value can be obtained from the formula Calculated, where To measure the area, The calculated charge transfer amount is used to further solve the corrosion current density , according to the formula , where the charge transfer coefficient It is usually determined by the polarization curve experiment of the material, and the value range is usually between 0.3 and 0.7. For example, for X60 grade pipeline steel, the experimental measurement is , assuming that the area of a certain measurement area , measuring time , the current response change per unit time The measured value is 2.5 mA, so the corrosion current density is calculated as follows:

[0132] ;

[0133] ;

[0134] This value reflects the corrosion current density per unit area and indicates the severity of the corrosion. Subsequently, the calculation result can be used to further analyze the corrosion rate trend.

[0135] The corrosion rate trend calculation submodule calls the corrosion current density and combines the polarization curve parameters of the material to calculate the dynamic change trend of the corrosion rate per unit time, adjusts the measurement rate increment, and obtains the dynamic change value of the corrosion rate.

[0136] First, we need to obtain the electrochemical polarization parameters of the material, including the anodic Tafel slope and the cathodic Tafel slope These parameters are usually determined by experiments. For example, for X60 pipe steel, , , based on the current density Calculating corrosion rates , calculated using Faraday's law:

[0137] ;

[0138] in is the molar mass of the metal (e.g. iron ), is the charge number (when iron corrodes ), is the Faraday constant ( ), is the metal density (the density of iron ), and substitute the above-calculated Perform the calculation:

[0139] ;

[0140] ;

[0141] The calculated result represents the trend of corrosion rate. Subsequently, the measured rate increment is adjusted to optimize the dynamic change value of corrosion rate, that is, the corrosion rate is calculated in different time intervals. , and calculate its relative rate of change:

[0142] ;

[0143] If at some point The corrosion rate Measured to be ,and The corrosion rate was measured to be ,but:

[0144] ;

[0145] This value is used to evaluate the changing trend of corrosion rate and, combined with long-term monitoring data, can be used to predict the development trend of corrosion.

[0146] See also Figure 5 , the corrosion risk distribution analysis module includes:

[0147] The corrosion rate distribution calculation submodule obtains corrosion rate data at multiple locations within a region based on the dynamic change value of the corrosion rate, calculates the corrosion rate change rate between adjacent locations, constructs a distribution matrix of corrosion rate changes in multiple regions, calculates the corrosion rate gradients at multiple points, and generates a corrosion rate gradient matrix;

[0148] First, multiple monitoring points are deployed in the selected area. Each monitoring point collects corrosion rate data through sensing equipment. The data collection frequency is set according to the accuracy of the equipment. For example, high-precision equipment can be set to once per minute, while ordinary precision equipment can be set to once per hour. The collected data is normalized and stored in the database. For the data of adjacent monitoring points, a change curve is drawn with time as the horizontal axis and corrosion rate as the vertical axis, and the corrosion rate change rate between each two adjacent points is calculated. The calculation formula is: ,in For the The corrosion rate at each location, is the corresponding timestamp. After the change rate data is stored, the corrosion rate change distribution matrix within the region is constructed. The matrix size is ,in Represents the number of rows, corresponding to the number of monitoring points in the vertical direction, Represents the number of columns, corresponding to the number of monitoring points in the horizontal direction. Based on the distribution matrix, the multi-point corrosion rate gradient is calculated. The gradient calculation adopts the numerical differentiation method, that is, and Calculate the gradient values in the horizontal and vertical directions respectively, and use the Euclidean norm to calculate the comprehensive gradient ,The calculated gradient data is stored in the gradient matrix, and the matrix size is consistent with the distribution matrix, as shown in Table 5.

[0149] Table 5 Corrosion rate gradient matrix

[0150]

[0151] As shown in Table 5, the corrosion rate gradient matrix can clearly reflect the changes in corrosion rate at each point in the region, and finally the corrosion rate gradient matrix is obtained.

[0152] The ratio-exceeding-standard area identification submodule calls the corrosion rate gradient matrix, calculates the local ratio of the corrosion rate change rate in multiple areas, sets a threshold, filters out areas with ratios exceeding the standard, calculates distribution characteristics, and obtains distribution parameters of the exceeding-standard areas;

[0153] For each area, the ratio of the local corrosion rate change rate is calculated as follows: ,in Set the exceeding threshold value for the average corrosion rate gradient of the area ,like , then the area is judged to be beyond the standard, the threshold Usually depends on industry standards or experimental values. For example, if the average corrosion rate gradient of a certain area is 0.15mm / a, , then the corresponding excessive corrosion rate threshold is mm / a, and the areas that meet the conditions are selected as the areas exceeding the standard. The distribution parameters of the areas exceeding the standard are counted, including the number of areas exceeding the standard, area proportion, and maximum and minimum corrosion gradient ratio, as shown in Table 6.

[0154] Table 6 Distribution parameters of areas exceeding the standard

[0155]

[0156] As shown in Table 6, the specific distribution information of the exceeding-standard area is obtained by calculating the distribution parameters of the exceeding-standard area.

[0157] The hotspot range gradient calculation submodule calls the distribution parameters of the exceeding area, adjusts the scanning step size, and compares the corrosion rate change gradient of the local area using the formula:

[0158] ;

[0159] Calculate and obtain the distribution parameters of corrosion hot spots;

[0160] in, represents the corrosion hotspot distribution parameter, Representative The corrosion rate gradient value at each location, Representative The scanning step length of the positions, Representative The excess ratio of each region, Representative The difference in the gradient of the neighborhood corrosion rate of each region, Represents the total number of calculation points in the area.

[0161] First, set the scan step size Set it as a fixed value, such as 0.5m, scan each exceeding standard area in turn, and compare the corrosion rate gradient of the local area. The calculation formula is:

[0162] ;

[0163] in, For the The corrosion rate gradient value at each position is obtained from the gradient matrix. is the scanning step, set to 0.5m, is the excess ratio, obtained from the excess ratio area identification submodule, is the gradient difference of the neighborhood corrosion rate, which is calculated as follows:

[0164] ;

[0165] in is the number of monitoring points in the neighborhood, calculate When the value is set, it is assumed that there are 3 exceeding points in the area, and their parameters are as follows: mm / a, , - mm / a, , - mm / a, , ;

[0166] Substituting into the formula:

[0167] ;

[0168] Calculate each item:

[0169] ;

[0170] ;

[0171] ;

[0172] ;

[0173] The results show that the corrosion hotspot distribution parameters finally calculated are , which is used to characterize the distribution of corrosion hot spots.

[0174] See also Figure 6 , the environmental parameter compensation module includes:

[0175] The corrosion hotspot distribution calculation submodule calls the corrosion hotspot distribution parameters, analyzes the corrosion intensity change trend of differentiated areas, obtains the corrosion hotspot distribution data, calculates the pipeline wall thickness change rate based on the distribution data, screens the corrosion intensified areas, and calculates the corrosion growth rate data;

[0176] First, read and call the corrosion hotspot distribution parameters, which are calculated from the data collected in the early stage. Specifically, they include the corrosion rate of different areas of the pipeline, the change of wall thickness and the corresponding time span. For example, if the wall thickness of a certain pipeline area decreases from 8.5mm to 8.1mm within one year, the corrosion rate is calculated as mm / year, and then analyze the corrosion data of multiple monitoring points, and compare the wall thickness change rate of each area. If the change rate of a certain area is higher than the preset threshold, it is marked as an area of intensified corrosion. The preset threshold can be set according to industry standards. For example, if the threshold is set to 0.3mm / year, if the wall thickness reduction rate of a certain area is greater than 0.3mm / year (such as 0.35mm / year), it is considered that the corrosion in this area is intensified. The corrosion hotspot distribution data of the area of intensified corrosion is screened and its corrosion growth rate is calculated. The specific calculation method can use the growth rate formula:

[0177] ;

[0178] in, is the corrosion growth rate, and Respectively indicate time and The corrosion rate at time mm / year, mm / year, time interval Year, the result is mm / year 2 , and finally the corrosion growth rate data is obtained.

[0179] The operating environment monitoring submodule monitors the temperature, pressure, and flow rate of the pipeline operating environment based on the corrosion growth rate data, collects the operating parameters of the corresponding time period, and compares the variation range of the operating parameters to calculate the temperature-flow rate synergistic impact factor using the formula:

[0180] ;

[0181] Calculate and obtain the temperature-flow rate synergistic impact factor data to obtain the environmental impact coefficient;

[0182] in, represents the temperature-flow rate synergistic influence factor, 、 are the maximum and minimum operating temperatures, 、 are the maximum and minimum values of the operating flow rate, is the average pressure during the time period, is the set of corrosion influence coefficients corresponding to the corrosion growth rate data, is the number of selected corrosion hotspot areas;

[0183] formula:

[0184] ;

[0185] First, based on the corrosion growth rate data, identify the key pipeline areas that need to be monitored, and deploy sensors in these areas to collect temperature, pressure and flow rate data respectively. For example, the temperature range recorded at a monitoring point within 1 hour is and , the flow rate range is m / s and m / s, average pressure The corrosion influence coefficient is obtained by taking the average value of the pressure data in the same time period, such as 4.5MPa. According to the corrosion growth rate data, if the corrosion growth rate in a certain area is high, its Set to 0.6. Then calculate the temperature-flow rate synergistic influence factor:

[0186] ;

[0187] Get the environmental impact coefficient , indicating that the temperature and flow velocity in this area fluctuate greatly, and have a stronger impact on the corrosion rate.

[0188] The disturbance amplitude adjustment submodule calls the environmental impact coefficient, analyzes the disturbance impact range, calculates the disturbance correction value according to the environmental impact coefficient, adjusts the disturbance amplitude, determines the disturbance adjustment interval, and calculates and obtains the environmental parameter compensation correction value.

[0189] First, call the calculated environmental impact coefficient to determine the scope of environmental impact on corrosion. For example, if This indicates that the environmental disturbance is large, and it may be necessary to increase the adjustment interval and correction amplitude. Set the baseline disturbance correction value to 0.05, and the calculation formula is as follows:

[0190] ;

[0191] Bring in Perform the calculation:

[0192] ;

[0193] The disturbance correction value is 0.249, and then the disturbance amplitude is adjusted. That is, by smoothing the monitoring data, for example, using the sliding window averaging method to calculate the average temperature and flow rate within 10 hours before and after the adjustment, adjusting the disturbance interval, and calculating the environmental parameter compensation correction value, such as the temperature correction value is 2.1°C, and the flow rate correction value is 0.15m / s. Ultimately, it is ensured that the calculated compensation correction value can accurately match the corrosion environment of the pipeline.

[0194] Table 7 Monitoring data examples

[0195]

[0196] As shown in Table 7, there are differences in temperature, flow rate, pressure and corrosion influence coefficient at different monitoring points. These parameters affect the final calculated temperature-flow rate synergistic influence factor, further guiding the disturbance correction and environmental parameter compensation calculation.

[0197] The above are merely preferred embodiments of the present invention and do not limit the present invention in any other form. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall still fall within the scope of protection of the technical solution of the present invention.

Claims

1. An intelligent pipeline corrosion monitoring and protection system, characterized in that: The system comprises: The dynamic potential disturbance measurement module obtains the reference potential of the pipeline surface, controls the potential source to apply instantaneous disturbance, adjusts the disturbance amplitude and records the current changes before and after the disturbance, and obtains the transient current change through differential operation; The local micro-area scanning module arranges a microelectrode array based on the transient current variation, detects the distribution of the transient current variation, determines the position of the microelectrode where the current variation is higher than a set threshold, adjusts the position of the microelectrode to cover the hot spot, records the local current response, calculates the current response gradient distribution, and obtains the local corrosion rate distribution value; The corrosion rate calculation module calculates the current response amplitude change rate based on the transient current change and the local corrosion rate distribution value, calculates the corrosion current density based on the electrochemical characteristics of the pipeline material, calculates the dynamic change trend of the corrosion rate per unit time based on the polarization curve parameters of the material, adjusts the measurement rate increment, and obtains the dynamic change value of the corrosion rate; The corrosion risk distribution analysis module calculates the corrosion rate change in the region based on the dynamic change value of the corrosion rate, generates a corrosion rate gradient matrix, analyzes the area where the local ratio exceeds the standard, adjusts the scanning step size, calculates the hot spot range gradient, and obtains the corrosion hot spot distribution parameters; The environmental parameter compensation module calls the corrosion hotspot distribution parameters, monitors the temperature, pressure and flow rate of the pipeline operating environment, calculates the environmental impact coefficient through the temperature-flow rate synergistic impact factor, calculates the disturbance correction value based on the environmental impact coefficient, adjusts the disturbance amplitude and interval, and calculates and obtains the environmental parameter compensation correction value; The corrosion protection control module intelligently adjusts the cathodic protection current or sacrificial anode configuration according to the corrosion hotspot distribution parameters and the dynamic change value of the corrosion rate, optimizes the corrosion protection measures, and dynamically adjusts the protection strategy to reduce the corrosion risk.

2. The intelligent pipeline corrosion monitoring and protection system according to claim 1 is characterized in that: The dynamic potential perturbation measurement module includes: The reference potential acquisition submodule obtains the pipeline surface potential, calls the reference electrode outside the pipeline to detect the reference potential, filters the potential data at different time points, calculates the potential fluctuation range, and selects the measured value in the potential stability interval as the pipeline surface reference potential; The disturbance potential applying submodule controls the potential source to output an instantaneous potential disturbance of a target amplitude based on the reference potential of the pipeline surface, adjusts the disturbance amplitude and records the current change on the pipeline surface after the disturbance, selects the disturbance data with stable current fluctuation value, and obtains the current change before and after the disturbance; The transient current calculation submodule uses the formula: ； Obtain the transient current change trend in multiple time periods, calculate and establish the transient current change; in, Represents the transient current change, Represents the first Current value at the moment, Represents the first Current value at the moment, Represents the number of time segments, represents the applied perturbation potential, represents the reference potential of the pipeline surface, Represents the equivalent resistance of the pipe surface.

3. The intelligent pipeline corrosion monitoring and protection system according to claim 2 is characterized in that: The local micro-area scanning module includes: The microelectrode placement submodule places a microelectrode array based on the transient current variation, detects the distribution of the transient current variation, determines the area where the current variation is higher than a set threshold, adjusts the microelectrode position to cover the hotspot, and generates a hotspot coverage placement state; The current response recording submodule calls the hotspot coverage layout state, records the local current response, obtains transient current data at multiple microelectrode positions, calculates the current response gradient distribution, and generates a current gradient distribution value; The local corrosion rate calculation submodule calculates the distribution gradient based on the current gradient distribution value, obtains the microelectrode spacing, transient current change and current gradient distribution value, performs gradient calculation and weighted summation, and uses the formula: ； Obtain the local corrosion rate distribution value; in, represents the local corrosion rate distribution value, Representative The current change at each microelectrode position, Representative The distance between each microelectrode and the adjacent microelectrode, is the number of microelectrodes.

4. The intelligent pipeline corrosion monitoring and protection system according to claim 3 is characterized in that: The corrosion rate calculation module includes: The current change analysis submodule collects the current response data on the pipeline surface based on the transient current change and the local corrosion rate distribution value, calculates the amplitude change rate of the current response per unit time, analyzes the change trend of the current response over time, and obtains the current response amplitude change rate; The corrosion current density calculation submodule calls the current response amplitude change rate and combines the electrochemical characteristics of the pipeline material to calculate the charge transfer relationship in the local area during the corrosion process using the formula: ； The current density per unit area during the corrosion process is calculated to obtain the corrosion current density; in, represents the corrosion current density, Represents the change in current response per unit time, Represents the area of the measurement area, represents the charge transfer coefficient, represents the measurement time; The corrosion rate trend calculation submodule calls the corrosion current density, combines the polarization curve parameters of the material, calculates the dynamic change trend of the corrosion rate per unit time, adjusts the measurement rate increment, and obtains the dynamic change value of the corrosion rate.

5. The intelligent pipeline corrosion monitoring and protection system according to claim 4 is characterized in that: The corrosion risk distribution analysis module includes: The corrosion rate distribution calculation submodule obtains corrosion rate data at multiple locations within the region based on the dynamic change value of the corrosion rate, calculates the corrosion rate change rate between adjacent locations, constructs a distribution matrix of corrosion rate changes in multiple regions, calculates the corrosion rate gradients at multiple points, and generates a corrosion rate gradient matrix; The ratio exceeding standard region identification submodule calls the corrosion rate gradient matrix, calculates the local ratio of the corrosion rate change rate in multiple regions, sets a threshold, filters the regions where the ratio exceeds the standard, calculates the distribution characteristics, and obtains the distribution parameters of the exceeding standard regions; The hotspot range gradient calculation submodule calls the distribution parameters of the exceeding area, adjusts the scanning step size, compares the corrosion rate change gradient of the local area, and uses the formula: ； Calculate and obtain the distribution parameters of corrosion hot spots; in, represents the corrosion hotspot distribution parameter, Representative The corrosion rate gradient value at each location, Representative The scanning step length of the position, Representative The excess ratio of each region, Representative The difference in the gradient of the neighborhood corrosion rate of each region, Represents the total number of calculation points in the area.

6. The intelligent pipeline corrosion monitoring and protection system according to claim 5 is characterized in that: The environmental parameter compensation module includes: The corrosion hotspot distribution calculation submodule calls the corrosion hotspot distribution parameters, analyzes the corrosion intensity change trend of the differentiated areas, obtains the corrosion hotspot distribution data, calculates the pipeline wall thickness change rate based on the distribution data, screens the corrosion exacerbation area, and calculates the corrosion growth rate data; The operating environment monitoring submodule monitors the temperature, pressure and flow rate of the pipeline operating environment based on the corrosion growth rate data, collects the operating parameters of the corresponding time period, compares the variation range of the operating parameters, and calculates the temperature-flow rate synergistic impact factor using the formula: ； Calculate and obtain the temperature-flow rate synergistic impact factor data to obtain the environmental impact coefficient; in, represents the temperature-flow rate synergistic influence factor, 、 are the maximum and minimum operating temperatures, 、 are the maximum and minimum values of the operating flow rate, is the average pressure during the time period, is the set of corrosion influence coefficients corresponding to the corrosion growth rate data, is the number of selected corrosion hotspot areas; The disturbance amplitude adjustment submodule calls the environmental impact coefficient, analyzes the disturbance impact range, calculates the disturbance correction value according to the environmental impact coefficient, adjusts the disturbance amplitude, determines the disturbance adjustment interval, and calculates and obtains the environmental parameter compensation correction value.

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