Storage tank acoustic emission online remote monitoring system and method

Abstract

The invention relates to the technical field of storage tank detection, and discloses a storage tank acoustic emission online remote monitoring system and method.The system mainly comprises an acoustic emission device, an information transmission device, a state monitoring module, a power module, a storage module and an interaction module; the output end of the acoustic emission device is connected with the input end of the information transmission device; the output end of the information transmission device is in communication connection with the input end of the state monitoring module; the output end of the state monitoring module is connected with the input end of the interaction module and the input end of the storage module. The power supply module is connected with the state monitoring module, the interaction module and the storage module. The problems of high detection cost and long detection time during can opening detection are solved by adopting an acoustic emission technology, the problem that the acoustic emission technology needs to be detected on site in real time by workers is solved by combining an online remote monitoring system, and the detection cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of storage tank detection, and particularly relates to a storage tank acoustic emission on-line remote monitoring system and method. Background Technique

[0002] Crude oil storage tanks are characterized by large scale and high risks. Once they fail, it will lead to oil leakage, and even fire and explosion accidents, causing casualties, property losses, and environmental damage, bringing great negative impacts to society. The storage tank is a storage tank with a volume greater than 100 cubic meters, and the storage tanks in oil and gas treatment projects can reach 50,000 cubic meters or even larger. Therefore, the condition monitoring of storage tanks is particularly important. Through previous experience and after multiple in-tank inspections of storage tanks, it is confirmed that the bottom plate of oilfield storage tanks is the area with the most serious corrosion. However, each in-tank inspection process includes processes such as shutdown, emptying, cleaning, and inspection, which have deficiencies such as high cost and long inspection time.

[0003] Acoustic emission technology is one of the most widely used detection technologies in the on-line detection of storage tank bottom plates at present. It can detect the corrosion of the tank bottom without opening the tank, solving the deficiencies of in-tank inspection. However, the existing acoustic emission detection devices cannot achieve real-time detection of storage tanks. They can only be used in indoor tests and on-site inspections, cannot detect the corrosion information of storage tanks in real time, lack the application of using this technology to monitor storage tanks in real time, and have high labor costs. Summary of the Invention

[0004] In order to solve the problems of high cost and long inspection time of existing in-tank inspections, and the inability of existing acoustic emission technologies to monitor in real time and high labor costs, the present invention proposes a storage tank acoustic emission on-line remote monitoring system and method.

[0005] In order to achieve the above-mentioned invention purposes, the technical solution of the present invention is as follows: On the one hand, the present invention provides a storage tank acoustic emission on-line remote monitoring system. The system includes an acoustic emission device, an information transmission device, a status monitoring module, a power supply module, a storage module, and an interaction module; the output end of the acoustic emission device is connected to the input end of the information transmission device; the output end of the information transmission device is communicatively connected to the input end of the status monitoring module; the output end of the status monitoring module is respectively connected to the input end of the interaction module and the input end of the storage module; the power supply module is respectively connected to the status monitoring module, the interaction module, and the storage module; wherein, The acoustic emission device is used to collect the status information of the storage tank and transmit the information to the information transmission device; The information transmission device is used to transmit the received status information of the storage tank to the status monitoring module; The status monitoring module is used to process the received status information of the storage tank, classify the risk level of the storage tank, and send the classified data to the interaction module and the storage module; An interaction module, configured to display the hierarchical data sent by the status monitoring module and obtain the operation instructions fed back by the operator according to different risk levels of the storage tank; A power supply module, configured to supply power to the status monitoring module, the interaction module and the storage module in the monitoring system.

[0006] Preferably, in the present invention, the information transmission device includes a resistor R1, a variable resistor R2, a resistor R3, a resistor R4, a resistor R5, a resistor R6, a resistor R7, a capacitor C1, a capacitor C2, a variable capacitor C3, a capacitor C4, a capacitor C5, a capacitor C6, an inductor L1, an inductor L2, a diode D1, a diode D2, a triode T1, a triode T2, a triode T3 and an antenna; one end of the resistor R1 is respectively connected to one end of the power supply, one end of the resistor R3, one end of the resistor R5 and one end of the capacitor R6; the other end of the resistor R1 is connected to a fixed end of the variable resistor R2; the other fixed end of the variable resistor R2 is respectively connected to the positive electrode of the diode D1, the source electrode of the triode T1, one end of the resistor R4, one end of the capacitor C2 and one end of the variable capacitor C3; the sliding end of the variable resistor R2 is connected to the negative electrode of the diode D2; the positive electrode of the diode D2 is respectively connected to the negative electrode of the diode D1 and the gate of the triode T1; the drain of the triode T1 is respectively connected to the other end of the resistor R3 and the gate of the triode T2; the source of the triode T2 is connected to the other end of the resistor R4; the drain of the triode T2 is respectively connected to the other end of the variable capacitor C3, the source of the triode T3 and one end of the capacitor C4; the other end of the resistor R5 is respectively connected to the other end of the capacitor C6, one end of the capacitor C1, one end of the inductor L1 and one end of the resistor R7; the other end of the capacitor C1 is connected to one end of the resistor R6; the other end of the resistor R6 is respectively connected to the other end of the capacitor C2 and the gate of the transistor T3; the drain of the transistor T3 is respectively connected to one end of the inductor L2, the other end of the capacitor C4 and one end of the capacitor C5; the other end of the inductor L2 is respectively connected to the other end of the inductor L1 and the other end of the resistor R7; the other end of the capacitor C5 is connected to the antenna.

[0007] On the other hand, the present invention also provides an on-line remote monitoring method for acoustic emission of a storage tank. The method is implemented based on the above remote monitoring system and mainly includes the following steps: S1. The acoustic emission device collects the status information of the storage tank at a set frequency to obtain the collected data; S2. Process the collected data and transmit the processed data to the status monitoring module through the information transmission device; S3. The status monitoring module checks the received data, removes the abnormal data, and obtains the processed data; S4. The status monitoring module divides the risk levels of the storage tank based on the processed data, obtains the classified data, and sends the classified data to the interaction module and the storage module; S5. The interaction module displays the classified data transmitted by the status monitoring module. Meanwhile, the user selects different processing methods for the storage tank through the interaction module according to the risk level data of the storage tank.

[0008] Preferably, in the present invention, the step S2 specifically includes the following contents: S2-1. Take a 32-bit keyword key from the collected data, and compress the collected data into 64 32-bit data; S2-2. Perform a logical operation on the 32-bit data and the keyword key to obtain the first data block; S2-3. Add the high 16 bits and the low 16 bits in the first data block and extend it to 32 bits to obtain the second data block; S2-4. Use the second data block as the 32-bit data and repeat steps S2-2 to S2-3 until 64 rounds to obtain the first intermediate hash value; S2-5. Use the remainder obtained by dividing the first intermediate hash value by a random number m less than 32 bits as the hash value; S2-6. Repeat steps S2-2 to S2-5 until all 64 32-bit data are converted into hash values, and sort the hash values to obtain the final hash value; S2-7. Pack the final hash value, the collected data, the keyword key, and the random number m and send them to the status monitoring module through the information transmission device.

[0009] Preferably, in the present invention, the step S3 specifically includes the following contents: S3-1. The status monitoring module receives the information transmitted by the information transmission device; S3-2. Obtain the corresponding final hash value for the collected data in the received information in the same way as in step S2. If the obtained final hash value is equal to the received hash value, go to step S3-3; otherwise, discard the received data and go to step S3-1; S3-3. Compare the received information with the historical data. If the data is abnormal, receive the information at the next moment and go to step S3-4; otherwise, use the received information as the processed data and go to step S4; S3-4. If the information at the next moment is still abnormal data, use the received information as the processed data and go to step S4; otherwise, use the average value of the historical data as the processed data and go to step S4.

[0010] Preferably, in the present invention, the step S5 includes the following content: If the current storage tank is of low risk, the interaction module displays that the current storage tank is in good condition; if the current storage tank is of medium risk, the interaction module displays that there is a risk in the current storage tank, please handle it quickly, and list the detailed information; if the current storage tank is of high risk, the interaction module displays that there is a high risk in the current storage tank, and list the detailed information.

[0011] Advantages of the present invention: 1. The present invention uses acoustic emission technology to avoid the problems of high detection cost and long detection time during open-tank detection, and combines an online remote monitoring system to avoid the problem that acoustic emission technology requires on-site real-time detection by staff, reducing the detection cost.

[0012] 2. The present invention uses a hash function to avoid possible transmission errors during information transmission, simplifies the calculation amount, and has high operating efficiency; it can rate the status of the storage tank and automatically alarm when a danger is found. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The foregoing and following specific descriptions of the present invention become clearer when read in conjunction with the following drawings, in which: Figure 1 is the system framework diagram of the present invention; Figure 2 is the circuit diagram of the information transmission device of the present invention; Figure 3 is the monitoring flow chart of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0014] In order to enable those skilled in the art to better understand the technical solutions in the present invention, the following will further illustrate the technical solutions for achieving the object of the present invention through several specific embodiments. It should be noted that the technical solutions claimed by the present invention include but are not limited to the following embodiments. Based on the embodiments in the present invention, all other embodiments obtained by those skilled in the art without creative efforts shall fall within the protection scope of the present invention.

[0015] Acoustic emission technology is one of the most widely used detection technologies in the on-line detection of the bottom plate of storage tanks at present. It can detect the corrosion of the tank bottom without opening the tank, solving the deficiencies of open-tank detection. However, the existing acoustic emission detection devices cannot achieve real-time detection of storage tanks. They can only be used in indoor tests and on-site detections, and cannot detect the corrosion information of storage tanks in real time. There is a lack of application of using this technology to monitor storage tanks in real time, and the labor cost is high.

[0016] Based on this, the present invention proposes a storage tank acoustic emission on-line remote monitoring system and method. The present invention uses acoustic emission technology to avoid the problems of high detection cost and long detection time during open-tank inspection, and combines with an on-line remote monitoring system to avoid the problem that acoustic emission technology requires on-site real-time detection by staff, reducing the detection cost.

[0017] Embodiment 1 As a specific implementation manner of a storage tank acoustic emission on-line remote monitoring system of the present invention, as shown in the attached drawings of the specification, Figure 1 the system includes an acoustic emission device, an information transmission device, a status monitoring module, a power supply module, a storage module, and an interaction module; the output end of the acoustic emission device is connected to the input end of the information transmission device; the output end of the information transmission device is communicatively connected to the first input end of the status monitoring module; the first output end of the status monitoring module is connected to the first input end of the interaction module; the second output end of the status monitoring module is mutually connected to the first input end of the storage module; the output end of the power supply module is connected to the second input end of the status monitoring module, the second input end of the interaction module, and the second input end of the storage module; wherein, The acoustic emission device is used to collect the corrosion signal of the storage tank and transmit the collected signal to the information transmission device; The information transmission device is used to transmit the corrosion signal of the storage tank collected by the acoustic emission device to the status monitoring module; The status monitoring module is used to process the received corrosion signal of the storage tank, classify the risk level of the storage tank, and send the classified data to the interaction module and the storage module; The interaction module is used to display the classified data sent by the status monitoring module and obtain the operation instructions made by the operator according to the data of different risk levels of the storage tank; The power supply module is used to supply power to the status monitoring module, the interaction module, and the storage module in the monitoring system.

[0018] In the present invention, the information transmission device only needs to be able to realize real-time data transmission, and either a wired network or a wireless network can be used.

[0019] In the present invention, in addition to storing the data generated by the status monitoring module, the storage module usually also stores the data generated during the operation of the entire system, such as the operation instructions and other data fed back by the operator through the interaction module.

[0020] In the present invention, the corrosion data of the storage tank collected by the acoustic emission device usually includes ring count, amplitude, energy, rise time, etc.

[0021] In the present invention, the acoustic emission device and the information transmission device can be devices with their own power supplies, or can be powered by other devices or structures.

[0022] Further, referring to the appended drawings of the specification Figure 2 , in order to improve the convenience and flexibility of system data transmission, the information transmission device realizes data transmission in a wireless transmission manner. The circuit structure of the information transmission device is specifically as follows: The information transmission device includes a resistor R1, a variable resistor R2, a resistor R3, a resistor R4, a resistor R5, a resistor R6, a resistor R7, a capacitor C1, a capacitor C2, a variable capacitor C3, a capacitor C4, a capacitor C5, a capacitor C6, an inductor L1, an inductor L2, a diode D1, a diode D2, a triode T1, a triode T2, a triode T3, and an antenna; one end of the resistor R1 is respectively connected to one end of the power supply, one end of the resistor R3, one end of the resistor R5, and one end of the capacitor R6; the other end of the resistor R1 is connected to a fixed end of the variable resistor R2; the other fixed end of the variable resistor R2 is respectively connected to the positive electrode of the diode D1, the source electrode of the triode T1, one end of the resistor R4, one end of the capacitor C2, and one end of the variable capacitor C3; the sliding end of the variable resistor R2 is connected to the negative electrode of the diode D2; the positive electrode of the diode D2 is respectively connected to the negative electrode of the diode D1 and the gate of the triode T1; the drain of the triode T1 is respectively connected to the other end of the resistor R3 and the gate of the triode T2; the source of the triode T2 is connected to the other end of the resistor R4; the drain of the triode T2 is respectively connected to the other end of the variable capacitor C3, the source of the triode T3, and one end of the capacitor C4; the other end of the resistor R5 is respectively connected to the other end of the capacitor C6, one end of the capacitor C1, one end of the inductor L1, and one end of the resistor R7; the other end of the capacitor C1 is connected to one end of the resistor R6; the other end of the resistor R6 is respectively connected to the other end of the capacitor C2 and the gate of the transistor T3; the drain of the transistor T3 is respectively connected to one end of the inductor L2, the other end of the capacitor C4, and one end of the capacitor C5; the other end of the inductor L2 is respectively connected to the other end of the inductor L1 and the other end of the resistor R7; the other end of the capacitor C5 is connected to the antenna.

[0023] Embodiment 2 As a specific implementation manner of an on-line remote monitoring method for acoustic emission of a storage tank according to the present invention, referring to the appended drawings of the specification Figure 3 shown, the method mainly includes the following steps: Step S1. Use an acoustic emission device to collect the corrosion signals of the storage tank at a set frequency to obtain the collected data.

[0024] In the present invention, the data collection frequency of the acoustic emission device is usually customized by the user according to the actual situation, for example, 1 second / time.

[0025] Step S2. Process the collected data and transmit it to the status monitoring module through the information transmission device.

[0026] In the present invention, the specific implementation manner of step S2 is as follows: Step S2-1. Take a 32-bit keyword key from the collected data, and compress the collected data into 64 32-bit data; Step S2-2. Perform a logical operation on the 32-bit data and the keyword key to obtain a first data block; Step S2-3. Add the high 16 bits and the low 16 bits in the first data block and extend it to 32 bits to obtain a second data block; Step S2-4. Use the second data block as the 32-bit data and repeat steps S2-2 to S2-3 until 64 rounds to obtain a first intermediate hash value; Step S2-5. Use the remainder obtained by dividing the first intermediate hash value by a random number m less than 32 bits as the hash value; Step S2-6. Repeat steps S2-2 to S2-5 until all 64 32-bit data are converted into hash values, sort the obtained 64 hash values to obtain a final hash value set; Step S2-7. Package the final hash value set, the collected data, the keyword key, and the random number m and send them to the status monitoring module using an information transmission device.

[0027] Step S3. The status monitoring module receives the collected data, checks the received data, and removes abnormal data to obtain processed data.

[0028] In the present invention, it should be noted that the data processing process involved in step S2 can be processed by an additional data processing module in the system, and then the data processing module transmits the data to the status monitoring module through the information transmission device.

[0029] Step S3. The status monitoring module receives the data transmitted by the information transmission device, checks the received data, and removes abnormal data to obtain processed data.

[0030] In the present invention, the specific implementation manner of step 3 is as follows: Step S3-1. The status monitoring module receives the information transmitted by the information transmission device; Step S3-2. The status monitoring module obtains the corresponding final hash value for the collected data in the received information in the same way as in step S2. If the obtained final hash value is equal to the received hash value, go to step S3-3; otherwise, discard the received data and go to step S3-1 to receive the information transmitted by the information transmission device again; S3-3. Compare the received information with historical data. If the data is abnormal, receive the information at the next moment and proceed to step S3-4; otherwise, use the received information as the processed data and proceed to step S4. S3-4. If the information at the next moment is still abnormal data, use the received information as the processed data and proceed to step S4; otherwise, use the average value of the historical data as the data at the current moment, that is, the processed data, and proceed to step S4.

[0031] In the present invention, theoretically, adjacent corrosion data is basically unchanged. For example, if a certain data is greater than 50% in this group (which can be set according to actual needs), this value can be considered abnormal.

[0032] Step S4. The status monitoring module divides the risk level of the storage tank based on the processed data and historical experience, obtains the classified data, and sends the classified data to the interaction module and the storage module.

[0033] In the present invention, the risk level can be divided by the user by defining corresponding rules. Usually, the storage tank can be divided into three levels: low risk, medium risk, and high risk. Different risk levels correspond to different processing methods.

[0034] Step S5. The interaction module displays the classified data transmitted by the status monitoring module and obtains the processing methods made by the user according to different risk levels.

[0035] In the present invention, the specific implementation method of step S5 is as follows: Judge the risk level of the current storage tank. If the current storage tank is of low risk, display on the display screen of the interaction module that the current storage tank is in good condition; if the current storage tank is of medium risk, display on the display screen of the interaction module that the current storage tank has risks and please handle it quickly, and list the detailed information; if the current storage tank is of high risk, the status monitoring module will analyze the possible situations, display on the display screen of the interaction module that the current storage tank has high risks, list the detailed information, and at the same time, the status monitoring module will trigger the alarm device of the system and send the specific information to the remote management personnel.

[0036] In the present invention, the listed detailed information is usually a user-defined relevant information directory, which generally includes the name of the storage tank, the monitoring point number, the corrosion data of the storage tank, and the risk handling method, etc.

[0037] In the present invention, in addition to displaying the data transmitted by the status monitoring module in real time, the interactive module also provides the user with a series of processing methods for different risk levels. The user selects different processing methods according to the risk level of the storage tank and his or her own work experience, so that the system can obtain different operation instructions made by the user according to the different risk levels of the storage tank, and the operation instructions will also be stored in the storage module of the system.

[0038] In the present invention, the status monitoring module can transmit data to a remote manager by wireless transmission through a wireless transmission module. The wireless transmission module can be provided by the status monitoring module itself or can be one of the components of the online remote monitoring system.

[0039] The present invention reduces the monitoring cost of the storage tank, avoids possible transmission errors during information transmission, simplifies the amount of calculation, and has high operating efficiency; the status of the storage tank can be rated and an alarm can be automatically issued when danger is found.

[0040] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any simple modification or equivalent change made to the above embodiment based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. An on-line remote monitoring system for acoustic emission of storage tanks, characterized in that Including: An acoustic emission device, an information transmission device, a status monitoring module, a power supply module, a storage module, and an interaction module; the output end of the acoustic emission device is connected to the input end of the information transmission device; the output end of the information transmission device is communicatively connected to the input end of the status monitoring module; the output end of the status monitoring module is respectively connected to the input end of the interaction module and the input end of the storage module; the power supply module is respectively connected to the status monitoring module, the interaction module, and the storage module; wherein, The acoustic emission device is used to collect the status information of the storage tank and transmit the information to the information transmission device; The information transmission device is used to transmit the received status information of the storage tank to the status monitoring module; The status monitoring module is used to process the received status information of the storage tank, classify the risk level of the storage tank, and send the classified data to the interaction module and the storage module; The interaction module is used to display the classified data sent by the status monitoring module and obtain the operation instructions feedback by the operator according to different risk levels of the storage tank; The power supply module is used to supply power to the status monitoring module, the interaction module, and the storage module in the monitoring system.

2. The on-line remote monitoring system for acoustic emission of a storage tank according to claim 1, characterized in that, The information transmission device includes a resistor R1, a variable resistor R2, a resistor R3, a resistor R4, a resistor R5, a resistor R6, a resistor R7, a capacitor C1, a capacitor C2, a variable capacitor C3, a capacitor C4, a capacitor C5, a capacitor C6, an inductor L1, an inductor L2, a diode D1, a diode D2, a triode T1, a triode T2, a triode T3, and an antenna; one end of the resistor R1 is respectively connected to one end of the power supply, one end of the resistor R3, one end of the resistor R5, and one end of the capacitor R6; the other end of the resistor R1 is connected to a fixed end of the variable resistor R2; the other fixed end of the variable resistor R2 is respectively connected to the positive electrode of the diode D1, the source electrode of the triode T1, one end of the resistor R4, one end of the capacitor C2, and one end of the variable capacitor C3; the sliding end of the variable resistor R2 is connected to the negative electrode of the diode D2; the positive electrode of the diode D2 is respectively connected to the negative electrode of the diode D1 and the gate of the triode T1; the drain of the triode T1 is respectively connected to the other end of the resistor R3 and the gate of the triode T2; the source of the triode T2 is connected to the other end of the resistor R4; the drain of the triode T2 is respectively connected to the other end of the variable capacitor C3, the source of the triode T3, and one end of the capacitor C4; the other end of the resistor R5 is respectively connected to the other end of the capacitor C6, one end of the capacitor C1, one end of the inductor L1, and one end of the resistor R7; the other end of the capacitor C1 is connected to one end of the resistor R6; the other end of the resistor R6 is respectively connected to the other end of the capacitor C2 and the gate of the transistor T3; The drain of the transistor T3 is respectively connected to one end of the inductor L2, the other end of the capacitor C4, and one end of the capacitor C5; the other end of the inductor L2 is respectively connected to the other end of the inductor L1 and the other end of the resistor R7; the other end of the capacitor C5 is connected to the antenna.

3. An on-line remote monitoring method for acoustic emission of storage tanks, which is implemented based on the monitoring system described in any one of the above claims 1-2, and is characterized in that, Including the following steps: S1. The acoustic emission device collects the status information of the storage tank at a set frequency to obtain the collected data; S2. Process the collected data and transmit the processed data to the status monitoring module through the information transmission device; S3. The status monitoring module checks the received data, removes abnormal data, and obtains the processed data; S4. The status monitoring module divides the risk level of the storage tank according to the processed data, obtains the classified data, and sends the classified data to the interaction module and the storage module; S5. The interaction module displays the classified data transmitted by the status monitoring module. At the same time, the user selects different processing methods for the storage tank according to the risk level data of the storage tank through the interaction module.

4. The monitoring method of an on-line remote monitoring system for acoustic emission of a storage tank according to claim 3, characterized in that, The specific content of step S2 includes the following: S2-1. Take a 32-bit keyword key for the collected data and compress the collected data into 64 32-bit data; S2-2. Perform a logical operation on the 32-bit data and the keyword key to obtain the first data block; S2-3. Add the high 16 bits and the low 16 bits in the first data block and expand it to 32 bits to obtain the second data block; S2-4. Use the second data block as 32-bit data and repeat steps S2-2 to S2-3 until 64 rounds to obtain the first intermediate hash value; S2-5. Use the remainder obtained by dividing the first intermediate hash value by a random number m less than 32 bits as the hash value; S2-6. Repeat steps S2-2 to S2-5 until all 64 32-bit data are converted into hash values, and sort the hash values to obtain the final hash value; S2-7. Pack the final hash value, the collected data, the keyword key, and the random number m and send them to the status monitoring module through the information transmission device.

5. The on-line remote monitoring method for acoustic emission of a storage tank according to claim 3, characterized in that, The specific content of step S3 includes the following: S3-1. The status monitoring module receives the information transmitted by the information transmission device; S3-2. Obtain the corresponding final hash value for the collected data in the received information in the same way as in step S2. If the obtained final hash value is equal to the received hash value, go to step S3-3; otherwise, discard the received data and go to step S3-1; S3-3. Compare the received information with the historical data. If the data is abnormal, receive the information at the next moment and go to step S3-4; otherwise, use the received information as the processed data and go to step S4; S3-4. If the information at the next moment is still abnormal data, use the received information as the processed data and go to step S4; Otherwise, use the average value of the historical data as the processed data and go to step S4.

6. The on-line remote monitoring method for acoustic emission of a storage tank according to claim 3, characterized in that The specific content of step S5 includes the following: If the current storage tank is of low risk, the interaction module displays that the current storage tank is in good condition; if the current storage tank is of medium risk, the interaction module displays that the current storage tank has risks and requires quick processing, and lists the detailed information; if the current storage tank is of high risk, the interaction module displays that the current storage tank has high risks and lists the detailed information.

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