Oil and gas station process pipeline corrosion monitoring and early warning method and system

Abstract

The invention provides an oil and gas station process pipeline corrosion monitoring and early warning method and system, and relates to the technical field of pipeline monitoring and detection. According to the early warning method and system, parameter fluctuation change analysis is carried out on collected corrosion influence factors to divide a plurality of target process units, a reasonable corrosion monitoring point is selected by predicting the corrosion rate through the parameters of the corrosion influence factors, and a monitor is installed to monitor the wall thickness of a process pipeline. Performing process pipeline safety early warning analysis on the wall thickness data of the process pipeline to obtain an early warning result; the method can be matched with the environment where the process pipeline is located, the utilization rate of monitoring data is improved, reasonable corrosion monitoring points are selected, the safety management level of an oil and gas station is guided, the integrity management level of the oil and gas process pipeline is improved, the safe service life is prolonged, and corrosion monitoring efficiency is high.

Description

Technical Field

[0001] This invention mainly relates to the field of pipeline safety monitoring technology, specifically to a method and system for monitoring and early warning of corrosion in process pipelines at oil and gas stations. Background Technology

[0002] During the design, processing, laying, use, modification, and maintenance of pipelines, oil and gas companies may encounter factors detrimental to the safe operation of process pipelines. Common failure types include internal corrosion, external corrosion, cracking, and third-party damage. With continuous improvements in manufacturing processes, welding techniques, the performance of external anti-corrosion coatings, and daily management, failures caused by external corrosion, cracking, and third-party damage to process pipelines are becoming increasingly rare. Internal corrosion, however, is the most common and frequent failure type for gathering and transportation process pipelines. Any loss in the wall thickness direction due to corrosion in process pipelines will directly affect the integrity and safety of the pipeline structure, thereby increasing the risk of failure accidents, directly endangering life and property, and potentially causing environmental pollution and negative social impacts.

[0003] Corrosion monitoring is crucial for revealing corrosion processes and patterns, assessing the effectiveness of corrosion control, predicting remaining service life, and guiding the adoption of appropriate anti-corrosion measures in the field. It is of great significance for oil and gas field enterprises to effectively manage corrosion risks and understand the corrosion status of process pipelines to ensure safe production. However, current corrosion monitoring applications suffer from problems such as incompatibility between monitoring methods and the environment, unreasonable monitoring locations, and underutilization of monitoring data, resulting in poor monitoring effectiveness. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method and system for monitoring and early warning of corrosion in process pipelines of oil and gas stations, in order to address the shortcomings of the existing technology.

[0005] The technical solution of this invention to solve the above-mentioned technical problems is as follows: A method for monitoring and early warning of corrosion in process pipelines at oil and gas stations, comprising the following steps:

[0006] The parameters of corrosion-influencing factors in process pipelines were analyzed and varied in advance. Based on the analysis results, the process pipelines were divided into multiple target process units.

[0007] The corrosion rate is predicted based on the parameters of the corrosion influencing factors corresponding to each target process unit. The corrosion status of each target process unit is classified according to the predicted corrosion rate. Corrosion monitoring points are determined based on the corrosion level information corresponding to each target process unit. Monitoring instruments are installed at the corrosion monitoring points.

[0008] Multiple monitoring instruments are installed to monitor the wall thickness of process pipelines in each target process unit, and the monitored process pipeline wall thickness data is used to conduct process pipeline safety early warning analysis to obtain early warning results.

[0009] Another technical solution of the present invention to solve the above-mentioned technical problems is as follows: A corrosion monitoring and early warning system for process pipelines in oil and gas stations, comprising:

[0010] The process piping segmentation module is used to analyze the parameter fluctuations of corrosion influencing factors of pre-collected process piping, and to divide the process piping into multiple target process units based on the fluctuation results obtained from the analysis.

[0011] The monitoring point determination module is used to predict the corrosion rate based on the parameters of the corrosion influencing factors corresponding to each target process unit, classify the corrosion status of each target process unit according to the predicted corrosion rate, determine the corrosion monitoring point according to the corrosion level information corresponding to each target process unit, and install the monitoring instrument at the corrosion monitoring point.

[0012] The early warning module is used to monitor the wall thickness of process pipelines in each target process unit through multiple installed monitoring instruments, and to perform process pipeline safety early warning analysis on the monitored process pipeline wall thickness data to obtain early warning results.

[0013] The beneficial effects of this invention are: analyzing the parameter fluctuations of collected corrosion influencing factors to divide the process into multiple process units; predicting corrosion rates based on the parameters of corrosion influencing factors to select reasonable corrosion monitoring points; installing monitoring instruments to monitor the wall thickness of process pipelines; and performing process pipeline safety early warning analysis on the process pipeline wall thickness data to obtain early warning results. This invention can be matched with the environment in which the process pipeline is located, improve the utilization rate of monitoring data, select reasonable corrosion monitoring points, guide the safety management level of oil and gas stations, improve the integrity management level and safe service life of oil and gas process pipelines, and has high corrosion monitoring efficiency. Attached Figure Description

[0014] Figure 1 A flowchart of a corrosion monitoring and early warning method for process pipelines in oil and gas stations provided in an embodiment of the present invention;

[0015] Figure 2 This is a block diagram of a corrosion monitoring and early warning system for process pipelines in oil and gas stations provided in an embodiment of the present invention.

[0016] Figure 3 This is a process flow diagram of an oil and gas processing station provided in an embodiment of the present invention;

[0017] Figure 4 A schematic diagram of pipeline operating parameters provided in an embodiment of the present invention;

[0018] Figure 5 The target process unit partitioning result provided in the embodiments of the present invention;

[0019] Figure 6 This is a schematic diagram of the corrosion monitoring point layout at an oil and gas station provided in an embodiment of the present invention;

[0020] Figure 7 This is a schematic diagram of the deployment scheme for corrosion monitoring devices at oil and gas stations provided in an embodiment of the present invention;

[0021] Figure 8 This is a schematic diagram illustrating the installation result of the monitoring instrument provided in an embodiment of the present invention. Detailed Implementation

[0022] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0023] This invention proposes an online corrosion monitoring and early warning method, including a monitoring location selection method, monitoring device and installation, and safety early warning method, aiming to improve the integrity management level and safe service life of oil and gas process pipelines.

[0024] like Figure 1 As shown, a corrosion monitoring and early warning method for process pipelines in oil and gas stations includes the following steps:

[0025] The parameters of corrosion-influencing factors in process pipelines were analyzed and varied in advance. Based on the analysis results, the process pipelines were divided into multiple target process units.

[0026] The corrosion rate is predicted based on the parameters of the corrosion influencing factors corresponding to each target process unit. The corrosion status of each target process unit is classified according to the predicted corrosion rate. Corrosion monitoring points are determined based on the corrosion level information corresponding to each target process unit. Monitoring instruments are installed at the corrosion monitoring points.

[0027] Multiple monitoring instruments are installed to monitor the wall thickness of process pipelines in each target process unit, and the monitored process pipeline wall thickness data is used to conduct process pipeline safety early warning analysis to obtain early warning results.

[0028] In the above embodiments, the collected corrosion influencing factors are analyzed for parameter fluctuations to divide the process into multiple process units. The corrosion rate is predicted by the parameters of the corrosion influencing factors to select reasonable corrosion monitoring points. Monitoring instruments are installed to monitor the wall thickness of the process pipelines. The process pipeline wall thickness data is analyzed to obtain early warning results. This invention can match the environment in which the process pipelines are located, improve the utilization rate of monitoring data, select reasonable corrosion monitoring points, guide the safety management level of oil and gas stations, improve the integrity management level and safe service life of oil and gas process pipelines, and has high corrosion monitoring efficiency.

[0029] Preferably, the analysis involves pre-collecting parameter fluctuations of corrosion-influencing factors in the process pipeline, and dividing the process pipeline into multiple target process units based on the fluctuation results obtained from the analysis, including:

[0030] Based on the different materials and transported substances, the process piping is divided into multiple process units. Process piping parameters are collected for each process unit, and corrosion-influencing parameters are selected from these parameters. These corrosion-influencing parameters include the partial pressure of CO2, the partial pressure of H2S, and the partial pressure of Cl corresponding to each process piping unit. - Concentration and temperature;

[0031] The partial pressures of CO2, H2S, and Cl corresponding to each process piping unit were calculated. - The concentration and temperature are compared with the corresponding set thresholds. If both are less than the threshold, the process unit is set as the target process unit, thereby obtaining multiple target process units.

[0032] In the above embodiments, corrosion-affecting parameters that have a significant impact on the process pipeline are selected from the initial process pipeline parameters, and their fluctuations are analyzed. The target process unit is then determined based on the fluctuations.

[0033] Preferably, the process piping is divided into multiple process units based on the different materials and transported substances, including:

[0034] When the process pipeline section is made of corrosion-resistant or non-metallic material, or when the medium transported in the process pipeline section is dry gas or water-free crude oil, the process pipeline section is set to not require monitoring; otherwise, the process pipeline section is set to be monitored, thereby obtaining multiple process units.

[0035] In the above embodiments, non-corroding process pipeline sections can be excluded, and easily corroded process pipeline sections can be used as process units to be monitored, thereby improving the efficiency and accuracy of pipeline corrosion monitoring.

[0036] Preferably, the step of predicting the corrosion rate based on the parameters of corrosion influencing factors corresponding to each target process unit includes:

[0037] The level values ​​of each corrosion influencing parameter are calculated using the formula for calculating the level values ​​of corrosion influencing factors. The formula for calculating the level values ​​of corrosion influencing factors is as follows:

[0038] A = 2a1 / (a max -a min )-(a max +a min ) / (a max -a min ),

[0039] B = 2b1 / (b max -b min )-(b max +b min ) / (b max -b min ),

[0040] C = 2c1 / (c max -c min )-(c max +c min ) / (c max -c min ),

[0041] D = 2d1 / (d max -d min )-(d max +d min ) / (d max -d min ),

[0042] Where A, B, C, and D are the partial pressures of CO2, H2S, and Cl, respectively. - Level values ​​of concentration and temperature, a max and a min These are the maximum and minimum values ​​of CO2 partial pressure at the oil and gas station, respectively, in MPa; b max and b min These are the maximum and minimum partial pressures of H2S at the oil and gas station, respectively, in MPa; c max and c min They are respectively oil and gas station Cl - Maximum and minimum concentrations, in mg / L; d max and d min These represent the maximum and minimum temperatures at the oil and gas station, in °C; a1, b1, c1, and d1 represent the partial pressures of CO2, H2S, and Cl in each target process unit, respectively. - Maximum values ​​for concentration and temperature, in °C;

[0043] Substitute the partial pressures of CO2, H2S, and Cl into the corrosion rate formula. - Corrosion rate is predicted by considering concentration and temperature levels to obtain the corrosion rate for each target process unit. The corrosion rate formula is as follows:

[0044]

[0045] Where X is the corrosion rate, and the unit is mm / a.

[0046] Preferably, the step of classifying the corrosion status of each target process unit according to the predicted corrosion rate includes:

[0047] The predicted corrosion rates for each target process unit are matched with multiple preset classification indicators to obtain the corrosion level information corresponding to each target process unit. The multiple preset classification indicators include:

[0048] 1) If X < 0.13 mm / a, the corrosion level information corresponding to the target process unit is mild;

[0049] 2) If 0.13mm / a ≤ X < 0.2mm / a, the corrosion level information corresponding to the target process unit is medium;

[0050] 3) If 0.2mm / a ≤ X < 0.38mm / a, the corrosion level information corresponding to the target process unit is severe;

[0051] 4) If X ≥ 0.38 mm / a, the corrosion level of the target process unit is extremely severe;

[0052] The step of determining corrosion monitoring points based on the corrosion level information corresponding to each target process unit obtained from the division includes:

[0053] For the target process unit with extremely severe corrosion level information, three corrosion monitoring points were set up, located upstream, midstream and downstream of the corresponding target process unit;

[0054] For the target process unit with severe corrosion level information, two corrosion monitoring points are set up, located upstream and downstream of the corresponding target process unit, respectively;

[0055] For the target process unit with a corrosion level of medium, one corrosion monitoring point is set up, located upstream of the corresponding target process unit;

[0056] No corrosion monitoring points are set up for target process units with a corrosion level of mild.

[0057] In the above embodiments, the corrosion rate can be accurately predicted based on the parameters of corrosion influencing factors corresponding to each target process unit. The location and number of corrosion monitoring points can be determined by the predicted corrosion rate, which improves the accuracy of pipeline monitoring data, enhances the compatibility of monitoring methods with the environment, avoids the problem of excessive design, and saves production costs.

[0058] Preferably, the installation of the monitoring instrument at the corrosion monitoring point includes:

[0059] When the corrosion monitoring point is a straight pipe, install the monitor at the bottom of the process pipeline where liquid is likely to accumulate. When the corrosion monitoring point is a bend, install the monitor at a 45° angle to the outer arc side of the bend. Use an angle grinder to remove the paint from the selected location on the straight pipe or bend, with a grinding area of ​​4cm x 4cm, to expose the metallic color. Then, use 240-grit and 400-grit sandpaper to grind the surface in sequence, ensuring no oil stains, dust, or other impurities remain. Next, use quick-drying adhesive to bond the monitor to the ground area, applying pressure to ensure a tight fit between the adhesive surface and the mounting point. Wrap the bottom edge of the monitor with glue. After installation, apply grease to the monitor housing. If the process pipeline has insulation, create an opening in the insulation to expose the monitor, and seal the gap between the monitor and the insulation housing with sealant. This completes the monitor installation.

[0060] Preferably, the process pipeline wall thickness monitoring of each target process unit is performed using multiple installed monitoring instruments, and the process also includes the step of building a monitoring platform.

[0061] The monitoring platform includes a gateway and a server. Each of the monitoring instruments is connected to the server through the gateway. The monitoring instrument sends the detected process pipeline wall thickness data to the server. The server is used to perform process pipeline safety early warning analysis on the detected process pipeline wall thickness data and obtain early warning results.

[0062] Specifically, gateway installation: The gateway should be fixed at a high position, at least 2 meters above the ground, using self-drilling screws. The gateway power cord and network cable should be run through PVC conduit. The network cable should be connected to the switch in the oil and gas station's server room or equipment room.

[0063] The server is installed in the server rack room or computer room of the oil and gas station, and the network cable is connected to the switch. The monitoring platform can be accessed by opening a browser on an office computer on the same network as the server and entering the specified URL.

[0064] Preferably, the step of performing process pipeline safety early warning analysis on the detected process pipeline wall thickness data to obtain early warning results includes:

[0065] The detected process pipeline wall thickness data is analyzed using a future wall thickness ratio formula to obtain early warning results.

[0066]

[0067] Where γ is the future wall thickness ratio, t c The monitored process piping wall thickness is in mm; t is the original wall thickness of the process piping in mm; σ is the design corrosion allowance of the process piping in mm.

[0068] The future wall thickness ratio is matched with the set early warning threshold.

[0069] When γ < 0.2, the resulting warning is unsafe.

[0070] When γ ≥ 0.7, the resulting warning is considered very safe.

[0071] When 0.2 ≤ γ < 0.7, the warning result is to continue using it under monitoring.

[0072] Preferably, the step of performing process pipeline safety early warning analysis on the detected process pipeline wall thickness data further includes:

[0073] When there are multiple corrosion monitoring points in the same target process unit, the minimum value γ is selected from the future wall thickness ratios corresponding to the multiple corrosion monitoring points, and the minimum value γ is used as the future wall thickness ratio result of this target process unit.

[0074] In the above embodiments, by performing process pipeline safety early warning analysis on the detected process pipeline wall thickness data, the future wall thickness ratio is obtained. Then, by setting an early warning threshold, it is determined whether the process pipeline corresponding to the future wall thickness ratio is safe and can continue to be used, thus obtaining a relatively complete monitoring result.

[0075] The following uses an oil and gas processing station as an example to illustrate the corrosion monitoring and early warning method for process pipelines in oil and gas stations according to the present invention.

[0076] The oil and gas medium first enters the valve group area, then enters the production separator for gas-liquid separation. The separated liquid is mainly formation water, which is transported to the wastewater treatment plant. The separated gas is mainly natural gas, which is cooled by a heat exchanger before entering the feed gas separator for gas-liquid separation. The gas from the feed gas separator is then transported after passing through a desulfurization and decarbonization unit. The liquid separated from the feed gas separator is also transported to the wastewater treatment plant. Liquid from the drying pond also enters the wastewater treatment plant and is then transported to injection wells for reinjection underground. Figure 3 As shown.

[0077] Step 1: Filter monitoring locations.

[0078] (1) Collect corrosion parameters

[0079] Corrosion parameters of process pipelines were collected, and the results are as follows: Figure 4 As shown.

[0080] (2) Divide the process units

[0081] Since the process piping from the valve group area to the production separator is made of stainless steel, the process piping from the wastewater treatment plant to the water injection well is made of fiberglass, and the process piping from the raw material separator to the desulfurization and decarbonization unit to the external transmission network contains dry gas, corrosion is not a concern in principle. Therefore, according to the principle of process unit division, these issues are not considered. Ultimately, this oil and gas station is planned to be divided into 5 target process units, such as... Figure 5 As shown.

[0082] (3) Based on the collected corrosion parameters of the oil and gas station and the unit division results, the corrosion rate of each unit was calculated. The results are shown in Table 2. Table 2 is the prediction result of pipeline corrosion rate.

[0083] Table 2

[0084]

[0085] (4) Corrosion rate classification

[0086] The corrosion rates of each unit were classified, and Table 3 shows the results of the corrosion rate classification.

[0087] Table 3

[0088] unit Classification Unit 1 serious Unit 2 Extremely serious Unit 3 Extremely serious Unit 4 moderate Unit 5 Mild

[0089] (5) Determine the monitoring sites

[0090] Based on the corrosion rate classification results, a total of nine monitoring points were ultimately set up in the upstream and downstream of Unit 1, the upstream, middle and downstream of Units 2 and 3, and the upstream of Unit 4. Figure 6 As shown in the figure. Meanwhile, during actual installation, obstructions should be avoided, and the system must be easy to install, operate, and maintain. The results of the monitoring point selection are shown in Table 4, which presents the screening results for corrosion monitoring points.

[0091] Table 4

[0092] Serial Number Installation location 1 The first bend at the liquid phase outlet of the production separator 2 The first bend before the sewage treatment plant exits the ground 3 The first bend at the gas phase outlet of the production separator 4 The straight pipe section after the second bend at the gas phase outlet of the production separator 5 Heat exchanger inlet straight pipe section 6 First bend at the heat exchanger outlet 7 Straight pipe section after the second bend at the heat exchanger outlet 8 First elbow at the inlet of the raw gas separator 9 First elbow at the liquid phase outlet of the feed gas separator

[0093] Step 2: Monitoring device and installation.

[0094] Because the wastewater treatment plant is far from the oil and gas treatment system, two gateways were selected, and the corrosion monitoring scheme was designed as follows: Figure 7 As shown.

[0095] (1) Monitoring instrument

[0096] The monitor consists of an ultrasonic measurement sensor and a high-capacity lithium battery. It adopts an integrated design and transmits data to a remote monitoring platform through a wireless sensor network. The main technical parameters are shown in Table 5. Table 5 shows the technical parameters of the wireless corrosion monitor.

[0097] Table 5

[0098] project Technical indicators Probe type Wideband narrow pulse probe Wireless data transmission protocol 4G wireless Battery 3.3Ah Lithium-ion ER14335x2 sampling frequency Collect one set of corrosion monitoring data daily. Shell material Weather-resistant engineering plastics and metals Explosion-proof rating Intrinsically safe Exd ib ⅡC T6 Gb Protection level IP67 Installation method Adhesion, magnetic assistance Thickness measurement range 3mm~50mm Thickness measurement accuracy ±0.02mm Temperature of the pipe under test -40℃～85℃

[0099] (2) Monitoring Platform

[0100] 1. Gateway

[0101] The wireless gateway's wireless communication network conforms to the IEEE 802.15.4 standard protocol. It features self-organizing networking capabilities; when a monitoring device experiences an anomaly in the wireless transmission, the network can automatically find an optimized transmission path to ensure continuous and reliable data transmission. The wireless gateway connects to the server via a dedicated cable or fiber optic cable. Wireless gateway product attributes:

[0102] 1) Private protocol;

[0103] 2) Long-distance communication, with a maximum distance of up to 300m from the monitoring instrument;

[0104] 3) Intelligent self-organizing network;

[0105] 4) Time-division multiplexing and multi-channel mounting are adopted;

[0106] 5) Supports wired WAN / LAN ports and SIM cards, offering a variety of network connection options;

[0107] 6) The network port supports speeds of 10 / 100Mbps;

[0108] 7) Supports one Wi-Fi wireless LAN;

[0109] 8) Supports VPN (PPTP / L2TP), PPPoE, DHCP, static IP and other functions;

[0110] 9) Supports MQTT / socket connection to the server;

[0111] 10) Supports multiple communication indicator lights;

[0112] 11) Supports one-click factory reset;

[0113] 12) Explosion-proof rating is EX ia IIC T6 Ga;

[0114] 13) Protection rating is IP67;

[0115] 14) Install by bolt fastening.

[0116] 2. Monitoring equipment

[0117] The monitoring equipment consists of online corrosion monitoring software, a database, and a server. The system software uses a B / S architecture; the analysis software can be accessed by entering the URL in a Google or Baidu browser. The monitoring equipment enables remote control of the wireless corrosion monitor, displays the relationship between pipe thickness and time, and sets alarms. Product attributes of the monitoring equipment:

[0118] 1) Adaptive elastic scaling supports tens of millions of concurrent connections;

[0119] 2) Data visualization display;

[0120] 3) Supports public / private / hybrid cloud deployment;

[0121] 4) Based on standard protocol API interfaces, it supports secondary development and integration with third-party systems;

[0122] 5) It can obtain the trend curve of thickness value within a specified historical period, and can also export the query data to a local file in tabular form;

[0123] 6) A specific thickness value or an alarm value obtained by another algorithm can be set as the threshold for early warning information.

[0124] (4) On-site installation

[0125] Nine corrosion monitoring instruments for the pipeline are connected to the gateway via 4G wireless, and the gateway uploads the data to the monitoring equipment via Ethernet.

[0126] 1) Monitor Installation: At the determined monitoring location, remove the external insulation of the pipe. Use an angle grinder to sand off the paint on the pipe surface in an area of ​​4cm x 4cm, exposing the metallic color. Then, sand with 240-grit and 400-grit sandpaper alternately, with the sanding directions perpendicular to each other. The surface should be free of residual oil stains, dust, and other impurities. Clean with alcohol. Then, use special metal welding AB glue to adhesively install the monitor at the sanded area, applying pressure to ensure a tight fit between the sensor's adhesive surface and the mounting point surface. The glue should cover the bottom edge of the sensor. After installation, apply grease to the monitor casing to isolate it from the air. Make a suitable hole in the pipe insulation layer to expose the monitor, and seal the gap between the monitor and the insulation shell with sealant. Then, use aluminum foil to tightly adhere the surrounding area to prevent rainwater from entering the insulation layer. Figure 8 As shown.

[0127] 1. Gateway Installation: One gateway is fixed to the roof of the control room of the oil and gas station using self-drilling screws, and the other gateway is fixed to the outer wall of the power distribution room of the sewage treatment plant (2.5m above the ground) using self-drilling screws. The power cord and network cable of the gateway are run through PVC conduit, and the network cable is plugged into the switches in the power distribution room of the oil and gas station and the power distribution room of the sewage treatment plant, respectively.

[0128] 2. Monitoring Platform Installation: The server is installed in the power distribution room of the oil and gas station, and the network cable is connected to the switch. The monitoring platform can be accessed by opening a browser on an office computer in the central control room, which is on the same network as the server, and entering the specified URL.

[0129] Step 3: Pipeline Safety Early Warning

[0130] After one year of continuous monitoring, the future wall thickness ratio of the process piping for the five process units was calculated based on the wall thickness obtained from the monitoring. The results show that the process piping of target process unit 1, target process unit 2, target process unit 3, and target process unit 4 are all "very safe", as shown in Table 6. Table 6 shows the calculation results of the process piping safety warning.

[0131] Table 6

[0132]

[0133]

[0134] After eight years of continuous monitoring, the CO2 and H2S content in the produced medium of the oilfield has increased, as has the water content. Based on the wall thickness obtained from the monitoring, the future wall thickness ratio of the process pipelines in five units was calculated. The results show that the process pipelines in Units 1 and 3 are "to continue to be used under monitoring", the process pipelines in Unit 2 are "unsafe", and the process pipelines in Unit 4 are "very safe", as shown in Table 7. Table 7 shows the calculation results of the safety warning for the process pipelines.

[0135] Table 7

[0136]

[0137]

[0138] By deploying corrosion monitoring devices at representative locations in oil and gas stations through the above steps, safety warnings can be issued based on the monitoring results, guiding the safety management level of oil and gas stations and improving the integrity management level and safe service life of oil and gas pipelines.

[0139] like Figure 2 As shown in the figure, this embodiment of the invention also provides a corrosion monitoring and early warning system for process pipelines in oil and gas stations, including:

[0140] The process piping segmentation module is used to analyze the parameter fluctuations of corrosion influencing factors of pre-collected process piping, and to divide the process piping into multiple target process units based on the fluctuation results obtained from the analysis.

[0141] The monitoring point determination module is used to predict the corrosion rate based on the parameters of the corrosion influencing factors corresponding to each target process unit, classify the corrosion status of each target process unit according to the predicted corrosion rate, determine the corrosion monitoring point according to the corrosion level information corresponding to each target process unit, and install the monitoring instrument at the corrosion monitoring point.

[0142] The early warning module is used to monitor the wall thickness of process pipelines in each target process unit through multiple installed monitoring instruments, and to perform process pipeline safety early warning analysis on the monitored process pipeline wall thickness data to obtain early warning results.

[0143] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0144] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the above-described apparatus and unit can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0145] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed.

[0146] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments of the present invention, depending on actual needs.

[0147] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0148] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0149] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for monitoring and early warning of corrosion in process pipelines at oil and gas stations, characterized in that, Includes the following steps: The parameters of corrosion-influencing factors in process pipelines were analyzed and varied in advance. Based on the analysis results, the process pipelines were divided into multiple target process units. The corrosion rate is predicted based on the parameters of the corrosion influencing factors corresponding to each target process unit. The corrosion status of each target process unit is classified according to the predicted corrosion rate. Corrosion monitoring points are determined based on the corrosion level information corresponding to each target process unit. Monitoring instruments are installed at the corrosion monitoring points. Multiple monitoring instruments are installed to monitor the wall thickness of process pipelines in each target process unit, and the monitored process pipeline wall thickness data is used to conduct process pipeline safety early warning analysis to obtain early warning results.

2. The method for monitoring and early warning of corrosion in process pipelines at oil and gas stations according to claim 1, characterized in that, The analysis pre-collected parameter fluctuations of corrosion-influencing factors in the process pipelines. Based on the fluctuation results obtained from the analysis, the process pipelines are divided into multiple target process units, including: Based on the different materials and transported substances, the process pipelines are divided into multiple process units, and process pipeline parameters are collected for each process unit. Corrosion-affecting parameters are then selected from the multiple process pipeline parameters. The corrosion-affecting parameters include the partial pressure of CO2, partial pressure of H2S, concentration of Cl-, and temperature corresponding to each process pipeline unit. The partial pressure of CO2, partial pressure of H2S, concentration of Cl- and temperature of each process pipeline unit are compared with the corresponding set thresholds. If all are less than the threshold, the process unit is set as the target process unit, thereby obtaining multiple target process units.

3. The corrosion monitoring and early warning method for process pipelines in oil and gas stations according to claim 2, characterized in that, The process piping is divided into multiple process units based on the different materials and transported substances, including: When the process pipeline section is made of corrosion-resistant or non-metallic material, or when the medium transported in the process pipeline section is dry gas or water-free crude oil, the process pipeline section is set to not require monitoring; otherwise, the process pipeline section is set to be monitored, thereby obtaining multiple process units.

4. The corrosion monitoring and early warning method for process pipelines in oil and gas stations according to claim 2, characterized in that, The method of predicting the corrosion rate based on the parameters of corrosion influencing factors corresponding to each target process unit includes: The level values ​​of each corrosion influencing parameter are calculated using the formula for calculating the level values ​​of corrosion influencing factors. The formula for calculating the level values ​​of corrosion influencing factors is as follows: A=2a1 / (a max -the min )-(the max +a min ) / (the max -the min ), B=2b1 / (b max -b min )-(b max +b min ) / (b max -b min ), C=2c1 / (c max -c min )-(c max +c min ) / (c max -c min ), D=2d1 / (d max -d min )-(d max +d min ) / (d max -d min ), Where A, B, C, and D are the level values ​​of CO2 partial pressure, H2S partial pressure, Cl- concentration, and temperature, respectively. max and a min These are the maximum and minimum partial pressures of CO2 at the oil and gas station, respectively, in MPa; b max and b min These represent the maximum and minimum partial pressures of H2S at the oil and gas station, respectively, in MPa; c max and c min They are respectively oil and gas station Cl - Maximum and minimum concentrations, in mg / L; d max and d min These are the maximum and minimum temperatures of the oil and gas station, in °C; a1, b1, c1, and d1 are the maximum values ​​of CO2 partial pressure, H2S partial pressure, Cl- concentration, and temperature for each target process unit, respectively. Substitute the partial pressures of CO2, H2S, and Cl into the corrosion rate formula. - Corrosion rate is predicted by considering concentration and temperature levels to obtain the corrosion rate for each target process unit. The corrosion rate formula is as follows: Where X is the corrosion rate, and the unit is mm / a.

5. The corrosion monitoring and early warning method for process pipelines in oil and gas stations according to claim 4, characterized in that, The step of classifying the corrosion status of each target process unit based on the predicted corrosion rate includes: The predicted corrosion rates for each target process unit are matched with multiple preset classification indicators to obtain the corrosion level information corresponding to each target process unit. The multiple preset classification indicators include: 1) If X < 0.13 mm / a, the corrosion level information corresponding to the target process unit is mild; 2) If 0.13mm / a ≤ X < 0.2mm / a, the corrosion level information corresponding to the target process unit is medium; 3) If 0.2mm / a ≤ X < 0.38mm / a, the corrosion level information corresponding to the target process unit is severe; 4) If X ≥ 0.38 mm / a, the corrosion level of the target process unit is extremely severe; The step of determining corrosion monitoring points based on the corrosion level information corresponding to each target process unit obtained from the division includes: For the target process unit with extremely severe corrosion level information, three corrosion monitoring points were set up, located upstream, midstream and downstream of the corresponding target process unit; For the target process unit with severe corrosion level information, two corrosion monitoring points are set up, located upstream and downstream of the corresponding target process unit, respectively; For the target process unit with a corrosion level of medium, one corrosion monitoring point is set up, located upstream of the corresponding target process unit; No corrosion monitoring points are set up for target process units with a corrosion level of mild.

6. The corrosion monitoring and early warning method for process pipelines in oil and gas stations according to claim 1, characterized in that, The installation of monitoring instruments at corrosion monitoring points includes: When the corrosion monitoring point is a straight pipe, install the monitor at the bottom of the process pipeline where liquid is likely to accumulate. When the corrosion monitoring point is a bend, install the monitor at a 45° angle to the outer arc side of the bend. Use an angle grinder to remove the paint from the selected location on the straight pipe or bend, with a grinding area of ​​4cm x 4cm, to expose the metallic color. Then, use 240-grit and 400-grit sandpaper to grind it in sequence. Next, use quick-drying adhesive to bond the monitor to the ground area, applying pressure to ensure a tight fit between the adhesive surface of the monitor and the surface of the mounting point. Wrap the bottom edge of the monitor with glue. After installation, apply grease to the monitor housing. If the process pipeline has an insulation layer, make a hole in the insulation layer to expose the monitor, and seal the gap between the monitor and the insulation housing with sealant to complete the installation of the monitor.

7. The method for monitoring and early warning of corrosion in process pipelines at oil and gas stations according to claim 1, characterized in that, The process involves monitoring the pipe wall thickness of each target process unit using multiple installed monitoring instruments, and also includes the step of building a monitoring platform. The monitoring platform includes a gateway and a server. Each of the monitoring instruments is connected to the server through the gateway. The monitoring instrument sends the detected process pipeline wall thickness data to the server. The server is used to perform process pipeline safety early warning analysis on the detected process pipeline wall thickness data and obtain early warning results.

8. The method for monitoring and early warning of corrosion in process pipelines at oil and gas stations according to any one of claims 1 to 7, characterized in that, The process pipeline safety early warning analysis performed on the detected process pipeline wall thickness data yields the following early warning results: The detected process pipeline wall thickness data is analyzed using a future wall thickness ratio formula to obtain early warning results. Where γ is the future wall thickness ratio, t c The monitored process piping wall thickness is in mm; t is the original wall thickness of the process piping in mm; σ is the design corrosion allowance of the process piping in mm. The future wall thickness ratio is matched with the set early warning threshold. When γ < 0.2, the resulting warning is unsafe. When γ ≥ 0.7, the resulting warning is considered very safe. When 0.2 ≤ γ < 0.7, the warning result is to continue using it under monitoring.

9. The corrosion monitoring and early warning method for process pipelines in oil and gas stations according to claim 8, wherein the step of performing process pipeline safety early warning analysis on the detected process pipeline wall thickness data further includes: When there are multiple corrosion monitoring points in the same target process unit, the minimum value γ is selected from the future wall thickness ratios corresponding to the multiple corrosion monitoring points, and the minimum value γ is used as the future wall thickness ratio result of this target process unit.

10. A corrosion monitoring and early warning system for process pipelines in oil and gas stations, characterized in that, include: The process piping segmentation module is used to analyze the parameter fluctuations of corrosion influencing factors of pre-collected process piping, and to divide the process piping into multiple target process units based on the fluctuation results obtained from the analysis. The monitoring point determination module is used to predict the corrosion rate based on the parameters of the corrosion influencing factors corresponding to each target process unit, classify the corrosion status of each target process unit according to the predicted corrosion rate, determine the corrosion monitoring point according to the corrosion level information corresponding to each target process unit, and install the monitoring instrument at the corrosion monitoring point. The early warning module is used to monitor the wall thickness of process pipelines in each target process unit through multiple installed monitoring instruments, and to perform process pipeline safety early warning analysis on the monitored process pipeline wall thickness data to obtain early warning results.

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