Anti-corrosion pipeline suitable for oil and gas storage and transportation
By combining ceramic coatings, electrochemical sensors, and ultrasonic thickness gauges on the inner and outer walls of oil and gas pipelines, the problems of real-time monitoring and life prediction of corrosion prevention in oil and gas pipelines in existing technologies have been solved, thereby reducing corrosion rate and maintenance costs, and improving safety and monitoring coverage.
Patent Information
- Application Number
- CN202511460690.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-13
- Publication Date
- 2026-01-09
AI Technical Summary
Existing oil and gas pipeline corrosion protection technologies lack real-time monitoring and remaining life prediction, resulting in high costs and long cycles for periodic excavation and inspection, and the inability to fully cover corrosion conditions over long distances or in complex environments. Furthermore, single anti-corrosion coatings are prone to aging and cannot effectively prevent contact between internal and external corrosive media and the metal.
Ceramic coatings are applied to the inner and outer walls of oil and gas pipelines as internal and external anti-corrosion layers. Electrochemical sensors and ultrasonic thickness gauges are also used to construct physical barriers to block contact with corrosive media. Combined with a control system, the corrosion situation is monitored in real time and early warnings are issued. The corrosion rate is calculated using electrochemical sensors and the remaining lifespan is predicted using ultrasonic thickness gauges.
It achieves proactive corrosion protection for oil and gas pipelines, reduces corrosion rate, decreases maintenance costs, and improves safety. Real-time monitoring and early warning reduce manual inspections and improve the comprehensive coverage and prediction accuracy of pipeline corrosion.
Smart Images
Figure CN121296914A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of oil and gas pipeline corrosion protection technology, and in particular to a corrosion-resistant pipeline suitable for oil and gas storage and transportation. Background Technology
[0002] In the oil and gas storage and transportation sector, pipelines, as the core transport carrier, have long faced complex and harsh corrosive environments. This issue has become a key bottleneck restricting the safe and efficient transportation of oil and gas. Oil and gas media contain hydrogen sulfide (H2S), carbon dioxide (CO2), and chloride ions (Cl-). - Corrosive components such as sulfur dioxide and sulfur dioxide can chemically react with the metal inner wall of the pipeline. Simultaneously, the scouring effect of the flowing medium accelerates the damage to the inner anti-corrosion layer and metal loss, leading to thinning of the pipeline wall, pitting or ulceration of the inner wall, and in severe cases, leakage. When pipelines are buried underground or exposed to the open, moisture, salt, and microorganisms (such as sulfate-reducing bacteria) in the soil can cause electrochemical corrosion of the pipeline's outer wall. Open-air pipelines face erosion from atmospheric oxygen, rainwater, and ultraviolet radiation, causing the outer anti-corrosion layer to age and peel off, ultimately leading to corrosion of the metal substrate.
[0003] In existing technologies, pipeline corrosion protection relies solely on a single anti-corrosion coating. Whether it's the commonly used 3PE anti-corrosion layer, epoxy powder coating, or traditional asphalt anti-corrosion layer, these only physically isolate the pipeline from external corrosive media, such as moisture, salt, microorganisms in the soil, and corrosive components in the transported medium. Current pipeline corrosion protection technologies generally lack structures for real-time monitoring and remaining life prediction, requiring periodic excavation and inspection or manual patrols to assess pipeline corrosion status. Periodic excavation and inspection is not only costly, time-consuming, and inefficient, but also damages the surrounding soil structure and vegetation. Manual patrols are limited by the experience level of the inspectors and the working environment. For long-distance oil and gas pipelines, deeply buried municipal pipelines, or special sections crossing rivers or mountains, inspectors cannot provide comprehensive coverage and can only assess the corrosion through visual observation and random wall thickness checks, failing to gain a deep understanding of the corrosion situation on the inner wall of the pipeline and in areas where coating damage is hidden. Summary of the Invention
[0004] The purpose of this invention is to provide a corrosion-resistant pipeline suitable for oil and gas storage and transportation. An inner and outer anti-corrosion layer are respectively installed on the inner and outer walls of the pipeline to construct a physical barrier, blocking the contact between internal and external corrosive media and the pipeline metal from the source, delaying the corrosion reaction, and reducing the corrosion rate. The use of ceramic coatings for both the inner and outer anti-corrosion layers reduces the frequency of pipeline maintenance and replacement, saving maintenance costs. The installation of electrochemical sensors, ultrasonic thickness gauges, and a control system allows for real-time monitoring of the severity of pipeline corrosion, early detection and warning of potential corrosion hazards, improved safety, and reduced manual inspections.
[0005] To achieve the above objectives, the present invention provides a corrosion-resistant pipeline suitable for oil and gas storage and transportation, comprising a pipeline with an inner anti-corrosion layer coated on its inner wall and an outer anti-corrosion layer coated on its outer wall. An electrochemical sensor and an ultrasonic thickness gauge are installed on the pipeline, both connected to a control system. The control system includes a data acquisition module, a data processing module, a data transmission module, a display module, and an early warning module. The data acquisition module is used to collect data detected by the electrochemical sensor and the ultrasonic thickness gauge; The data processing module is used to predict the remaining life of the pipeline based on the data collected by the data acquisition module; The data transmission module is used to transmit the actual corrosion rate of the pipeline and the predicted remaining life of the pipeline obtained by the data processing module to the display module and the early warning module; The display module is used to display the calculated actual corrosion rate of the pipeline and the predicted remaining life; The early warning module is used to provide early warning when the actual corrosion rate of the pipeline changes rapidly.
[0006] Preferably, the electrochemical sensor includes a linear polarization resistance (LPR) sensor and an electrochemical noise (EN) sensor.
[0007] Preferably, the inner and outer anti-corrosion layers are made of ceramic coatings.
[0008] Preferably, the data processing module uses the linear polarization resistance (LPR) detected by the LPR sensor. Calculate the corrosion current density of pipe metal Then, based on the corrosion current density Calculate the actual corrosion rate Based on the actual corrosion rate obtained The actual wall thickness of the pipe as measured by an ultrasonic thickness gauge Predicting the minimum allowable wall thickness of the pipeline remaining lifespan before .
[0009] Preferably, the corrosion current density of the pipe metal The calculation formula is as follows: ; in, Let Tafel be the constant. Actual corrosion rate The calculation formula is as follows: ; in, For unit conversion factors, Let be the molar mass of the pipe metal. This represents the number of electrons transferred in the metal corrosion reaction. It is Faraday's constant. The density of the pipe metal; Predicting the remaining life of the pipeline The calculation formula is as follows: .
[0010] Therefore, the present invention employs the above-mentioned corrosion-resistant pipeline suitable for oil and gas storage and transportation, which specifically includes the following beneficial effects: (1) Active corrosion protection: An inner anti-corrosion layer and an outer anti-corrosion layer are set on the inner and outer walls of the pipeline respectively to build a physical barrier, block the contact between the internal and external corrosive media and the pipeline metal from the source, delay the occurrence of corrosion reaction, and reduce the corrosion rate. The inner and outer anti-corrosion layers are made of ceramic coating to reduce the frequency of pipeline maintenance and replacement, which can save maintenance costs. (2) Real-time corrosion monitoring and intelligent analysis and early warning: The installation of electrochemical sensors, ultrasonic thickness gauges and control systems can calculate the actual corrosion rate, predict the remaining life of the pipeline, observe the severity of corrosion in real time, detect potential corrosion hazards in advance and issue early warnings, improve safety and reduce manual inspections.
[0011] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description
[0012] Figure 1 This is a schematic diagram of a section of an anti-corrosion pipeline suitable for oil and gas storage and transportation according to the present invention. Figure 2 This is a cross-sectional view of a corrosion-resistant pipeline suitable for oil and gas storage and transportation according to the present invention.
[0013] Figure Labels 1. Pipeline; 2. Inner anti-corrosion layer; 3. Outer anti-corrosion layer; 4. Ultrasonic thickness gauge; 5. Linear polarization resistance (LPR) sensor; 6. Electrochemical noise (EN) sensor; 7. Control system. Detailed Implementation
[0014] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.
[0015] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.
[0016] Example 1 like Figures 1 to 2 As shown, this invention provides a corrosion-resistant pipeline suitable for oil and gas storage and transportation, comprising a pipeline 1, an inner anti-corrosion layer 2 coated on the inner wall of the pipeline 1, and an outer anti-corrosion layer 3 coated on the outer wall of the pipeline 1. Both the inner and outer anti-corrosion layers 2 and 3 are made of ceramic coatings. The inner and outer anti-corrosion layers 2 and 3 form a physical barrier, blocking the contact between internal and external corrosive media and the metal of the pipeline 1 at the source, delaying the corrosion reaction, and reducing the corrosion rate. The ceramic coating has high hardness, high density, high temperature resistance, and chemical corrosion resistance. Compared with traditional coatings, the ceramic coating has stronger adhesion and is less prone to peeling due to erosion or external environmental influences, thus reducing the corrosion rate inside and outside the pipeline and extending the protection period of the inner and outer anti-corrosion layers 2 and 3.
[0017] An electrochemical sensor and an ultrasonic thickness gauge 4 are installed on pipeline 1. The electrochemical sensor includes a linear polarization resistance (LPR) sensor 5 and an electrochemical noise (EN) sensor 6. These sensors are installed on the pipeline using existing technology. The ultrasonic thickness gauge 4 can detect the pipeline wall thickness, the LPR sensor 5 can quickly measure linear polarization resistance, and the EN sensor 6 can detect current and potential noise during the corrosion process, identifying localized corrosion risks such as pitting and crevice corrosion, thus compensating for the limitations of the LPR sensor 5 in monitoring localized corrosion. The ultrasonic thickness gauge 4, LPR sensor 5, and EN sensor 6 can collect real-time pipeline corrosion-related data such as corrosion current density and pipeline wall thickness changes, replacing traditional manual inspections and enabling continuous and dynamic monitoring of the pipeline corrosion status, allowing for timely detection of corrosion anomalies.
[0018] Both the electrochemical sensor and the ultrasonic thickness gauge 4 are connected to the control system 7. The control system 7 processes the monitoring data, calculates the actual corrosion rate, predicts the remaining lifespan of pipeline 1, and triggers early warnings when the corrosion rate changes rapidly. This provides maintenance personnel with accurate decision-making support and quantitative data for pipeline 1 replacement and maintenance planning, preventing major safety accidents such as oil and gas leaks, explosions, and fires caused by corrosion, thus ensuring the safety of maintenance personnel and the surrounding environment. The control system 7 includes a data acquisition module, a data processing module, a data transmission module, a display module, and an early warning module. The data acquisition module is used to acquire data detected by the electrochemical sensor and the ultrasonic thickness gauge 4; The data processing module is used to predict the remaining life of pipeline 1 based on the data collected by the data acquisition module; The data transmission module is used to transmit the actual corrosion rate of pipe 1 and the predicted remaining life of pipe 1 obtained by the data processing module to the display module and the early warning module. The display module is used to display the calculated actual corrosion rate of pipe 1 and the predicted remaining life; The early warning module is used to provide early warning when the actual corrosion rate of pipeline 1 changes rapidly.
[0019] The data processing module uses the linear polarization resistance (LPR) sensor to detect the linear polarization resistance. Calculate the corrosion current density of pipe metal Then, based on the corrosion current density Calculate the actual corrosion rate Actual corrosion rate It can reflect the current corrosion severity of the pipeline in real time. Based on the obtained actual corrosion rate... The actual wall thickness of the pipe as measured by an ultrasonic thickness gauge Predicting the minimum allowable wall thickness of the pipeline remaining lifespan before This provides a quantitative basis for the formulation of pipeline replacement and maintenance plans.
[0020] Corrosion current density of pipe metal The calculation formula is as follows: ; in, Let Tafel be the constant. Actual corrosion rate The calculation formula is as follows: ; in, For unit conversion factors, Let be the molar mass of the pipe metal. This represents the number of electrons transferred in the metal corrosion reaction. It is Faraday's constant. The density of the pipe metal; Predicting the remaining life of the pipeline The calculation formula is as follows: .
[0021] Therefore, the present invention employs the aforementioned anti-corrosion pipeline suitable for oil and gas storage and transportation. An inner anti-corrosion layer and an outer anti-corrosion layer are respectively set on the inner and outer walls of the pipeline to construct a physical barrier, blocking the contact between the internal and external corrosive media and the pipeline metal from the source, delaying the occurrence of corrosion reaction, and reducing the corrosion rate. The inner and outer anti-corrosion layers use ceramic coatings to reduce the frequency of pipeline maintenance and replacement, which can save maintenance costs. The installation of electrochemical sensors, ultrasonic thickness gauges, and control systems can monitor the severity of pipeline corrosion in real time, detect potential corrosion hazards in advance and issue early warnings, improve safety, and reduce manual inspections.
[0022] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.
Claims
1. A corrosion-resistant pipeline suitable for oil and gas storage and transportation, characterized in that: The system includes pipes with an inner anti-corrosion coating on the inner wall and an outer anti-corrosion coating on the outer wall. Electrochemical sensors and ultrasonic thickness gauges are installed on the pipes, both connected to a control system. The control system includes a data acquisition module, a data processing module, a data transmission module, a display module, and an early warning module. The data acquisition module is used to collect data detected by the electrochemical sensor and the ultrasonic thickness gauge; The data processing module is used to predict the remaining life of the pipeline based on the data collected by the data acquisition module; The data transmission module is used to transmit the actual corrosion rate of the pipeline and the predicted remaining life of the pipeline obtained by the data processing module to the display module and the early warning module; The display module is used to display the calculated actual corrosion rate of the pipeline and the predicted remaining life; The early warning module is used to provide early warning when the actual corrosion rate of the pipeline changes rapidly.
2. The corrosion-resistant pipeline suitable for oil and gas storage and transportation according to claim 1, characterized in that: Electrochemical sensors include linear polarization resistance (LPR) sensors and electrochemical noise (EN) sensors.
3. The corrosion-resistant pipeline suitable for oil and gas storage and transportation according to claim 1, characterized in that: The inner and outer anti-corrosion layers are made of ceramic coating.
4. The corrosion-resistant pipeline suitable for oil and gas storage and transportation according to claim 1, characterized in that: The data processing module uses the linear polarization resistance (LPR) sensor to detect the linear polarization resistance. Calculate the corrosion current density of pipe metal Then, based on the corrosion current density Calculate the actual corrosion rate Based on the actual corrosion rate obtained The actual wall thickness of the pipe as measured by an ultrasonic thickness gauge Predicting the minimum allowable wall thickness of the pipeline remaining lifespan before .
5. A corrosion-resistant pipeline suitable for oil and gas storage and transportation according to claim 4, characterized in that: Corrosion current density of pipe metal The calculation formula is as follows: ； in, Let Tafel be the constant. Actual corrosion rate The calculation formula is as follows: ； in, For unit conversion factors, Let be the molar mass of the pipe metal. This represents the number of electrons transferred in the metal corrosion reaction. It is Faraday's constant. The density of the pipe metal; Predicting the remaining life of the pipeline The calculation formula is as follows: 。