Corrosion monitoring device, pipeline environment monitoring device, and pipeline environment monitoring system

Abstract

The present disclosure relates to a corrosion degree monitoring device, a pipeline environment monitoring device and a pipeline environment monitoring system. The corrosion degree monitoring device comprises a device body, a first conductive module and a second conductive module arranged inside the device body for conducting current, a first current sensor and a second current sensor arranged inside the device body, the first current sensor being used for detecting a first current flowing through the first conductive module, and the second current sensor being used for detecting a second current flowing through the second conductive module, and a processor being used for determining a corrosion degree through a preset corrosion model according to the first current and the second current. The first conductive module is arranged on an outer wall in a bare manner, and the second conductive module is arranged in a sealed manner inside. Real-time corrosion data can be obtained, and an abnormal early warning can be performed, thereby solving the problems of low corrosion precision, poor real-time performance and inconvenient monitoring of the coupon method in the prior art.

Description

Technical Field

[0001] This disclosure relates to the field of corrosion monitoring technology, and in particular to a corrosion degree monitoring device, a pipeline environment monitoring device, and a pipeline environment monitoring system. Background Technology

[0002] Corrosion under insulation (CUI) is a corrosion phenomenon that occurs on the outer surface of pipes or equipment covered with insulation material. It is mainly divided into two types: corrosion on carbon steel and corrosion on stainless steel. The mechanism of this corrosion is complex and involves multiple factors, including temperature, humidity, and the properties of the insulation material.

[0003] Corrosion under the insulation layer is hidden and difficult to detect in time. Once it is discovered, it usually causes serious corrosion and damage. The causes of corrosion under the insulation layer mainly include: (1) Insulation layer material: The insulation layer material contains a large amount of inorganic salts, such as chlorides, fluorides, sulfides, etc., which are corrosive; (2) Insulation layer structure: The insulation layer is usually a loose and porous structure with a large specific surface area, and therefore has a strong water absorption capacity. Once the insulation layer is damaged, the insulation material will quickly absorb the surrounding water vapor, creating a high-humidity corrosive environment; (3) Temperature change: When the steel structure under the insulation layer undergoes thermal cycling, due to the difference in thermal expansion coefficient between the steel and the insulation layer, thermal cycling often leads to an increase in the internal stress of the coating, which eventually causes the coating to fail prematurely.

[0004] Under current technology, the dipstick method is commonly used to assess the corrosiveness of a material to an environment. The most intuitive way is to expose a material sample to the environment for a certain period of time and then measure the changes that occur in the material; this is the basis of the dipstick method. Although there are now rapid-response instruments for measuring metal corrosion, the dipstick method remains one of the most widely used methods for corrosion detection in process equipment. However, the dipstick method has limitations: it can only determine the average corrosion rate over the test period and is difficult to represent the corrosion situation when equipment process parameters change over a short period of time; in addition, it cannot reproduce localized corrosion effects well (such as pitting corrosion, erosion, and waterline corrosion).

[0005] Furthermore, the corrosion detection method using the hanging plate method has problems such as low accuracy, poor real-time performance, and inconvenient monitoring. The hanging plate method often requires waiting for a long time (it may take several months for changes to be seen in oil pipelines that have taken anti-corrosion measures), and it also requires disassembling the outer layer of the pipeline. Summary of the Invention

[0006] This disclosure provides a corrosion degree monitoring device, a pipeline environment monitoring device, and a pipeline environment monitoring system. The corrosion degree monitoring device can collect on-site corrosion degree and real-time corrosion information, enabling more accurate and real-time data acquisition. The pipeline environment monitoring system can provide early warnings of abnormal data, integrating the complete process of data acquisition, transmission, analysis, and processing, providing an efficient and intelligent solution for corrosion monitoring of oil pipelines. Through multi-layered design, the system can process data from various protocols, monitor corrosion in real time, and make corresponding decisions, effectively ensuring the safe operation of oil pipelines.

[0007] In a first aspect, this disclosure provides a corrosion degree monitoring device, comprising:

[0008] device body;

[0009] The first conductive module is disposed inside the main body of the device;

[0010] The second conductive module is disposed on the outer wall of the device body;

[0011] A first current sensor is disposed inside the device body and electrically connected to the first conductive module, and is used to detect the first current flowing through the first conductive module.

[0012] The second current sensor is disposed inside the device body and electrically connected to the second conductive module, and is used to detect the second current flowing through the second conductive module;

[0013] A processor, disposed inside the device body and electrically connected to the first current sensor and the second current sensor, is used to determine the degree of corrosion based on the first current and the second current.

[0014] The first conductive module is disposed in an exposed manner on the outer wall of the device body, while the second conductive module is disposed in a sealed manner inside the device body.

[0015] In some embodiments, both the first conductive module and the second conductive module comprise red copper.

[0016] In some embodiments, the processor is configured to determine the degree of corrosion based on the difference between the first current and the second current using a preset corrosion model.

[0017] In some embodiments, the preset corrosion model includes a first corrosion model, the first corrosion model comprising:

[0018] Y = dl * K1

[0019] Where Y represents the degree of corrosion; dl represents the current difference; and K1 is a constant.

[0020] In some embodiments, the preset corrosion model includes a second corrosion model, the second corrosion model including:

[0021]

[0022] Where Y represents the degree of corrosion; dl represents the current difference; and K2, K3, and K4 are all constants.

[0023] Secondly, this disclosure provides a pipeline environmental monitoring device, comprising:

[0024] The environmental monitoring device body is installed on the outer wall of the inner pipe of the pipeline;

[0025] The corrosion degree monitoring device described above is installed inside the environmental monitoring device body and exposes the first conductive module of the corrosion degree monitoring device so that the first conductive module is in contact with the environment outside the environmental monitoring device body;

[0026] A temperature sensor is installed inside the environmental monitoring device body to detect temperature data of the external environment of the environmental monitoring device body.

[0027] A humidity sensor is installed inside the environmental monitoring device body to detect humidity data of the external environment of the environmental monitoring device body;

[0028] A communication module, located inside the environmental monitoring device body, is communicatively connected to the control module and is used to receive data acquisition commands and / or provide feedback monitoring data; wherein, the monitoring data includes one or more of temperature data, humidity data, and corrosion degree;

[0029] The control module is located inside the environmental monitoring device and is communicatively connected to the corrosion monitoring device, the temperature sensor, and the humidity sensor, respectively, and is used to acquire the monitoring data in response to the data acquisition command.

[0030] Thirdly, this disclosure provides a pipeline environmental monitoring system, characterized in that it includes:

[0031] The pipeline environmental monitoring device described above;

[0032] The data acquisition device is electrically connected to the pipeline environmental monitoring device and is used to control the pipeline environmental monitoring device to feed back monitoring data.

[0033] The data processing subsystem is communicatively connected to the acquisition device and is used to analyze and process the monitoring data in order to issue an early warning when the monitoring data meets preset early warning conditions.

[0034] In some embodiments, the data acquisition device includes:

[0035] A battery is used to provide power to the pipeline environmental monitoring device.

[0036] An electrically controllable switch, one end of which is connected to the battery and the other end of which is connected to the pipeline environmental monitoring device;

[0037] The data acquisition control unit is electrically connected to the electrically controllable switch and is used to issue data acquisition commands to control the electrically controllable switch to be in a closed state, thereby activating the pipeline environment monitoring device and acquiring monitoring data through the pipeline environment monitoring device.

[0038] In some embodiments, the data acquisition control unit issues the data acquisition command at preset time intervals.

[0039] In some embodiments, the data acquisition and control unit is further configured to, in response to a customized data request, control the pipeline environment monitoring device to feed back monitoring data corresponding to the customized data request.

[0040] This disclosure provides a corrosion degree monitoring device, a pipeline environment monitoring device, and a pipeline environment monitoring system. The corrosion degree monitoring device can collect on-site corrosion degree and real-time corrosion conditions, enabling more accurate and real-time data acquisition. The pipeline environment monitoring system can provide early warnings of abnormal data, integrating the complete process of data acquisition, transmission, analysis, and processing, providing an efficient and intelligent solution for corrosion monitoring of oil pipelines. Through multi-layered design, the system can process data from various protocols, monitor corrosion conditions in real time, and make corresponding decisions, effectively ensuring the safe operation of oil pipelines. Because existing technologies (such as the plate-mounted method) require long waiting times (even for oil pipelines with anti-corrosion measures, changes may take months) and require disassembling the outer pipeline layer, this disclosure solves the problems of low corrosion acquisition accuracy, poor real-time performance, and inconvenience associated with the plate-mounted method. Attached Figure Description

[0041] The present disclosure will be described in more detail below based on embodiments and with reference to the accompanying drawings:

[0042] Figure 1 This is a schematic diagram of the structure of a corrosion monitoring device provided in an embodiment of the present disclosure;

[0043] Figure 2 A schematic diagram of a corrosion model provided in an embodiment of this disclosure;

[0044] Figure 3 This is a schematic diagram of the structure of a pipeline environmental monitoring device provided in an embodiment of the present disclosure;

[0045] Figure 4 This is a schematic diagram of the structure of a pipeline environmental monitoring system provided in an embodiment of the present disclosure;

[0046] Figure 5 This is a schematic diagram of a data acquisition device provided in an embodiment of the present disclosure;

[0047] Figure 6 This is a schematic diagram illustrating the relationship between a data acquisition device and a pipeline environmental monitoring device, provided in an embodiment of this disclosure.

[0048] Figure 7 This is a schematic diagram of the application architecture of a pipeline environmental monitoring system provided in an embodiment of the present disclosure;

[0049] Figure 8 This is a schematic diagram of the application architecture of another pipeline environmental monitoring system provided in an embodiment of this disclosure.

[0050] Figure label:

[0051] Figure 6 In the middle: 1-485 line, 2-pipeline environmental monitoring device, 3-data acquisition device, 4-outer pipe of oil pipeline, 5-insulation cotton, 6-inner pipe of oil pipeline.

[0052] In the accompanying drawings, the same parts are referred to by the same reference numerals, and the drawings are not drawn to scale. Detailed Implementation

[0053] To enable those skilled in the art to better understand the technical solutions of this disclosure, and to fully understand and implement the process of how this disclosure applies technical means to solve technical problems and achieve corresponding technical effects, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, not all embodiments. The embodiments of this disclosure and the various features within them can be combined with each other without conflict, and the resulting technical solutions are all within the protection scope of this disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without creative effort should fall within the protection scope of this disclosure.

[0054] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this disclosure described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0055] It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions, and although a logical order is shown in the flowchart, in some cases the steps shown or described may be executed in a different order than that shown here.

[0056] The following explanations will first describe some of the technical terms used in the embodiments of this application and / or the prior art, so that those skilled in the art can understand the technical solutions of this application:

[0057] Red copper, also known as pure copper or purple copper, has excellent electrical and thermal conductivity, excellent plasticity, and is easy to hot-press and cold-press. It is widely used in the manufacture of wires, cables, brushes, and EDM copper for electrical discharge machining, all products requiring good conductivity. Red copper, obtained by smelting sulfide or oxide copper ores, can be used for casting coins and making objects.

[0058] The RS-485 communication interface is a widely used method for remote weighing data acquisition when the communication distance is required to be from tens of meters to thousands of meters. RS-485 employs balanced transmission and differential reception, thus possessing the ability to suppress common-mode interference.

[0059] MQTT (Message Queuing Telemetry Transport) is a publish / subscribe messaging protocol based on the ISO standard (ISO / IEC PRF 20922). It operates on the TCP / IP protocol suite and is designed for remote devices with limited hardware performance and poor network conditions.

[0060] Modbus is a serial communication protocol published in 1979 by Modicon (now Schneider Electric) for communication using programmable logic controllers (PLCs). Modbus has become the industry standard for communication protocols in the industrial field and is now a common connection method between industrial electronic devices.

[0061] The plate-mounted corrosion test (PRT) is the most direct way to assess the corrosiveness of a material to an environment. It involves exposing a material sample to that environment for a certain period and measuring the changes that occur. This is the basis of the PRT. Although rapid-response instruments for measuring metal corrosion exist, the PRT remains one of the most widely used methods for corrosion detection in process equipment. The advantages of the PRT are that it allows for simultaneous comparative and parallel tests on many different materials, and it can determine the exact type of corrosion based on the sample. The limitations of the PRT are that it can only determine the average corrosion rate over the test period, making it difficult to represent the corrosion situation when equipment process parameters change over short periods; furthermore, it cannot accurately reproduce localized corrosion effects (such as pitting corrosion, erosion, and waterline corrosion). Compared to manual inspection (observing the corrosion of the plate), the cost is significantly reduced, and the monitoring effect is significantly improved.

[0062] In the technical solution disclosed herein, for corrosion monitoring: a material with good conductivity (capable of detecting minute changes in resistance and current, improving monitoring accuracy), high melting point, adaptability to the high-temperature environment of oil pipelines, and corrosion resistance (ensuring the service life of corrosion monitoring) is required; therefore, red copper is selected as the corrosive medium. For the data transmission protocol: short bytes for easy parsing are desired for rapid transmission and processing, enabling quick task completion and sleep mode entry, thus achieving energy saving; therefore, the Modbus protocol is selected. To facilitate expansion of the number of sensors (corrosion sensors) and ensure low power consumption during transmission, the RS-485 is selected. For convenient data reporting, it needs to adapt to various network conditions; given the coverage of 4G base stations, a 4G module is selected for data reporting.

[0063] Example 1

[0064] This embodiment provides a corrosion degree monitoring device.

[0065] Figure 1 This is a schematic diagram of the structure of a corrosion monitoring device provided in an embodiment of this disclosure, as shown below. Figure 1 As shown, the corrosion monitoring device disclosed in this embodiment includes:

[0066] device body;

[0067] The first conductive module is disposed inside the device body and is used to conduct current;

[0068] The second conductive module is disposed on the outer wall of the device body and is used to conduct current.

[0069] A first current sensor is disposed inside the device body and electrically connected to the first conductive module, and is used to detect the first current flowing through the first conductive module.

[0070] The second current sensor is disposed inside the device body and electrically connected to the second conductive module, and is used to detect the second current flowing through the second conductive module;

[0071] A processor, disposed inside the device body and electrically connected to the first current sensor and the second current sensor, is used to determine the degree of corrosion based on the first current and the second current.

[0072] The first conductive module is disposed in an exposed manner on the outer wall of the device body, while the second conductive module is disposed in a sealed manner inside the device body.

[0073] In some embodiments, both the first conductive module and the second conductive module comprise red copper.

[0074] When monitoring the degree of corrosion, based on the principle that the resistance value increases when red copper is corroded, a large number of current values ​​with different degrees of corrosion are collected under the same environment to determine a mathematical model for identifying the degree of corrosion, which is then used as a formula for calibrating the degree of corrosion (i.e., the preset corrosion model).

[0075] Specifically, two copper samples with identical characteristics are selected (ensuring consistent size and resistance). One sample is sealed as a reference to calculate the resistance difference relative to the reference. The other copper sample is exposed to the medium (oil pipeline) to allow corrosion. Then, the same voltage is applied to both copper samples, and the degree of corrosion is determined by the difference in current flowing through them using a pre-defined corrosion model.

[0076] In some embodiments, the processor determines the degree of corrosion based on the first current and the second current, which may specifically include:

[0077] The processor determines the degree of corrosion based on the difference between the first current and the second current using a preset corrosion model.

[0078] In some cases, when the charge is less than 33 nanoamps (nA), the degree of corrosion and the current difference are roughly linear, and the preset corrosion model can be expressed by the following formula:

[0079] Y = dl * K1

[0080] Where Y represents the degree of corrosion; dl represents the current difference; and K1 is a constant, which can be 0.256.

[0081] In some cases, when the charge is less than 33 nanoamps (nA), the preset corrosion model can be expressed by the following formula:

[0082]

[0083] Where Y represents the degree of corrosion; dl represents the current difference; K2, K3 and K4 are constants, and their values ​​can be 1.4, 0.021 and 5.63 respectively.

[0084] Furthermore, dividing the degree of corrosion by time yields the corresponding corrosion rate, expressed in μm / a, which represents micrometers per year.

[0085] Optionally, a schematic diagram of the preset corrosion model can be referenced. Figure 2 .

[0086] Example 2

[0087] Based on the above embodiments, this embodiment provides a pipeline environment monitoring device for monitoring the environment of a pipeline.

[0088] Figure 3 This is a schematic diagram of the structure of a pipeline environmental monitoring device provided in an embodiment of the present disclosure, as shown below. Figure 3 As shown, the pipeline environmental monitoring device disclosed in this embodiment includes:

[0089] The environmental monitoring device body is installed on the outer wall of the inner pipe of the pipeline;

[0090] The corrosion degree monitoring device described above is installed inside the environmental monitoring device body and exposes the first conductive module of the corrosion degree monitoring device so that the first conductive module is in contact with the environment outside the environmental monitoring device body;

[0091] A temperature sensor is installed inside the environmental monitoring device body to detect temperature data of the external environment of the environmental monitoring device body.

[0092] A humidity sensor is installed inside the environmental monitoring device body to detect humidity data of the external environment of the environmental monitoring device body;

[0093] A communication module, located inside the environmental monitoring device body, is communicatively connected to the control module and is used to receive data acquisition commands and / or provide feedback monitoring data; wherein, the monitoring data includes one or more of temperature data, humidity data, and corrosion degree;

[0094] The control module is located inside the environmental monitoring device and is communicatively connected to the corrosion monitoring device, the temperature sensor, and the humidity sensor, respectively, and is used to acquire the monitoring data in response to the data acquisition command.

[0095] The environmental monitoring device itself is installed on the outer wall of the inner pipe, and can be located inside the insulation cotton between the inner and outer pipes. For details, please refer to... Figure 6 .

[0096] As an example, in this pipeline environmental monitoring device, the first conductive module of the corrosion monitoring device installed on the outer wall of the pipeline is exposed, and thus the first conductive module is in contact with the environment outside the main body of the environmental monitoring device. Therefore, the first conductive module and the pipeline are in the same external environment.

[0097] As an example, this pipeline environmental monitoring device can output humidity data, temperature data, or corrosion level of the environment individually; it can also output any combination of two of these three types of data or all three types of data as needed.

[0098] Example 3

[0099] Based on the above embodiments, this embodiment provides a pipeline environment monitoring system, which can be used to monitor pipelines (such as oil pipelines) and related parameters of the environment in which the pipelines are located (such as parameters that affect the corrosion rate of the pipelines), and further analyze and process the monitoring data so that users can grasp the current corrosion status of the pipelines and related information about the environment in which the pipelines are located in real time.

[0100] Figure 4 This is a schematic diagram of the structure of a pipeline environmental monitoring system provided in an embodiment of the present disclosure, as shown below. Figure 4 As shown, the pipeline environmental monitoring system disclosed in this embodiment includes:

[0101] The pipeline environmental monitoring device described above;

[0102] The data acquisition device is electrically connected to the pipeline environmental monitoring device and is used to activate the pipeline environmental monitoring device and acquire monitoring data through the pipeline environmental monitoring device.

[0103] The data processing subsystem is communicatively connected to the acquisition device and is used to analyze and process the monitoring data in order to issue an early warning when the monitoring data meets preset early warning conditions.

[0104] It's important to note that when installing data acquisition devices and pipeline environmental monitoring devices at pipeline locations, it's necessary to determine the positional relationships and correspondences between the pipeline and these devices, as well as the correspondence between the acquisition devices and the monitoring devices themselves. After installation, the corresponding pipeline number, acquisition device number, and geographical coordinates are recorded in the database. Subsequently, based on the alerts, it's possible to determine which section of the pipeline has experienced severe corrosion.

[0105] In some embodiments, the data acquisition device includes:

[0106] A battery is used to provide power to the pipeline environmental monitoring device.

[0107] An electrically controllable switch, one end of which is connected to the battery and the other end of which is connected to the pipeline environmental monitoring device;

[0108] The data acquisition control unit is electrically connected to the electrically controllable switch and is used to issue data acquisition commands to control the electrically controllable switch to be in a closed state, thereby activating the pipeline environment monitoring device and acquiring monitoring data through the pipeline environment monitoring device.

[0109] In some embodiments, the data acquisition device further includes:

[0110] The data communication module is connected to the acquisition and control unit and is used to report the monitoring data.

[0111] In some embodiments, the data acquisition control unit issues the data acquisition command at preset time intervals.

[0112] In some embodiments, the data processing subsystem includes:

[0113] The gateway module is communicatively connected to the acquisition device and is used to encapsulate and process the monitoring data;

[0114] The protocol parsing module is communicatively connected to the gateway module and is used to parse and process the encapsulated data.

[0115] The business module is communicatively connected to the protocol parsing module and is used to perform corresponding business processing on the parsed data; wherein, the business processing includes: data monitoring, data storage and early warning processing.

[0116] In some embodiments, the business module includes:

[0117] A data monitoring unit is used to monitor the parsed data;

[0118] A log recording unit is used to save the parsed data to a preset time-series database;

[0119] The early warning unit is used to issue an early warning message when the data after parsing and processing meets the preset early warning conditions.

[0120] In some embodiments, the data monitoring unit includes:

[0121] The data inspection subunit is used to inspect and analyze the parsed data in order to determine the change pattern of the data to be monitored.

[0122] The data display subunit is used to display the data after parsing and / or the change patterns.

[0123] In some embodiments, the warning unit issues the warning message via a pop-up window and / or push notification; wherein the warning message includes one or more of the following: project information, pipeline information, corrosion level, temperature information, humidity information, time information, and location information.

[0124] In some embodiments, the data display subunit is also used to display the warning message and / or data in the preset time series database.

[0125] As an example, this system monitors pipelines and related parameters of their environment (such as parameters affecting pipeline corrosion rates) in the following ways:

[0126] (1) Monitor the corrosion level of the pipeline, which can be divided into 6 stages according to the corrosion level:

[0127] C1: Corrosion rate less than 9.67 μm / a, recommended measures: very low corrosivity, no protection required;

[0128] C2: Corrosion rate less than 32.39 μm / a, recommended measures: low corrosivity, light protection;

[0129] C3: Corrosion rate less than 107.39 μm / a, recommended measures: moderate corrosivity, attention should be paid to corrosion and protection;

[0130] C4: Corrosion rate less than 248.22 μm / a, recommended measures: high corrosiveness, key attention and protection;

[0131] C5: Corrosion rate less than 587.85um / a, recommended measures: highly corrosive, corrosion source needs to be identified on site;

[0132] CX: Corrosion rate greater than 587.85um / a, recommended measures: extremely high corrosion rate, corrosion source needs to be identified on site;

[0133] It should be noted that the preset warning conditions include corrosion levels of C4, C5, or CX, which can be set according to actual needs;

[0134] (2) Based on the fact that the resistance value will decrease as the temperature rises and the air humidity increases, the real-time corrosion model is calibrated based on the degree of corrosion, and the mathematical model is re-established for corrosion calibration to obtain the real-time corrosion rate.

[0135] (3) This yields relatively accurate corrosion data. The data acquisition device (i.e., the acquisition unit) acquires data via 485 line and Modbus protocol.

[0136] (4) Based on the high temperature characteristics of oil pipelines, the sensor and data acquisition components are made of high temperature resistant materials to avoid abnormal data acquisition situations (e.g., acquisition failure, delay, interference, etc.).

[0137] (5) Due to the long and variable length of oil pipelines, the 485 line is used to connect the data collectors in series, which can quickly expand the pipeline.

[0138] (6) Based on the sealing characteristics of oil pipelines, a battery is used to provide power to the collector;

[0139] (7) Based on the explosive danger of oil pipelines, explosion-proof batteries are selected. Insulation materials are added between the batteries, and explosion-proof shell materials are used on the shell material. In addition, the battery discharge status can be monitored and controlled through the battery chip to prevent the battery from being over-discharged.

[0140] (8) The data collector wakes up the pipeline environment monitoring device at regular intervals to collect data by configuring the collection time (the collection time here is the preset time interval at which the data collector issues the collection command; for example, it can be set to collect data once a week, once a day, or once an hour, etc.) in order to save electricity.

[0141] (9) The data collected by the collector is connected to the Internet via a 4G IoT card and reported via the MQTT protocol.

[0142] (10) The platform performs protocol parsing on the reported data to obtain the corresponding real-time corrosion data;

[0143] (11) On the one hand, real-time data is displayed on the visualization screen (i.e., the data display sub-unit) after it is obtained; on the other hand, real-time warnings are issued through preset warning thresholds, and relevant personnel can be reminded through SMS, voice and pop-up windows on the screen, so as to effectively handle abnormal situations in advance (such as excessive pipeline corrosion).

[0144] Optionally, a reminder can be sent via a pop-up window on a webpage. The reminder content may include:

[0145] A warning has been issued for project {project name} and device name at {location}. Please handle the warning promptly.

[0146] For example: Under the insulation layer of the project, the pipeline #7-2B before the pipeline issued an early warning at point 7, indicating that the corrosion level has reached C3. Please handle it in time.

[0147] In some embodiments, the data acquisition and control unit is further configured to, in response to a customized data request, control the pipeline environment monitoring device to feed back monitoring data corresponding to the customized data request.

[0148] Optionally, customized data requests can come from personalized customizations of business modules.

[0149] Optionally, the data acquisition device can receive power from an external source via a cable. In this case, the data acquisition device can remain in a wake-up state (also understood as an active state, capable of providing real-time feedback of detection data). At this time, the data acquisition control unit of the device can be used to respond to external customized data requests, controlling the pipeline environment monitoring device to feed back monitoring data corresponding to the customized data request.

[0150] For example, if you only want to know the temperature and humidity information of the environment where a certain pipeline is located, you can send a customized data request to the data acquisition device corresponding to that pipeline. The data acquisition device will then obtain the corresponding data from the corresponding pipeline environment monitoring device based on the customized data request.

[0151] In summary, this system can address the problems of low accuracy, poor real-time performance, and inconvenient monitoring associated with existing technologies (such as the plate-mounted method) for corrosion data acquisition. It can be used for real-time monitoring of the corrosion status and extent of corrosion in oil pipelines; it can collect real-time temperature, humidity, and corrosion data and report it to the cloud; it can efficiently monitor the status of refining pipelines in real time, providing early warnings of pipeline anomalies through preset thresholds, reducing the cost of manual inspections; it upgrades digital cloud services, coordinating the status of the entire industrial park, reducing management and maintenance costs, and facilitating data access and security; it provides an extra layer of security, further reducing the probability of safety risks; and it can perform real-time assessments of corrosion conditions.

[0152] Example 4

[0153] Based on the above embodiments, this embodiment provides an application example of a pipeline environmental monitoring system.

[0154] The data acquisition device / module is used to collect data (corrosion, temperature and humidity) from the corrosion module (i.e., pipeline environmental monitoring device). It is powered by an internal battery, has a timed wake-up function for data acquisition, and connects to the cloud gateway via MQTT. It collects real-time data from the corrosion module in batches, writes it to an SD card, and reports the collected data to the cloud gateway module via a 4G communication module.

[0155] refer to Figure 5 The data acquisition device includes a protective shell to protect the internal components and isolate them from the effects of moisture, dust, high temperature, and electromagnetic fields, so as not to affect the normal operation of the electronic components. The material is explosion-proof and meets the explosion-proof requirements of oil pipelines.

[0156] The data acquisition device includes a host unit consisting of a microcontroller and a 4G module. Internally, it implements sleep logic (timed sleep and wake-up to save power). After waking up, it acquires data from the 485-line series corrosion sensor and temperature and humidity sensor via the Modbus protocol. The acquired data is written to an SD card for easy export later. Then, based on the offset position of the last reported data (SD card), the data is packaged into JSON and reported to the cloud via the 4G module. After successful transmission, the offset position of the SD card is updated, and then the device enters sleep mode, waiting for the next wake-up.

[0157] The data acquisition device includes a battery box, which consists of a battery and a metal casing. The casing is made of explosion-proof material. The battery capacity is 3000mAh, which can meet the needs of long-term operation for 5-6 months. The battery is divided with heat-insulating material inside, and the discharge is controlled by a power chip to prevent over-discharge. It is connected to the main unit of the device and powered by an aviation plug.

[0158] The acquisition device includes an antenna to amplify the signal from the 4G module in the main unit. The antenna is connected to the main unit, and a hole is pre-drilled in the protective shell for the antenna to pass through, which is then sealed with rubber.

[0159] The corrosion monitoring device (corrosion module), temperature sensor, and humidity sensor are used to monitor the corrosion level, real-time corrosion status, and internal temperature and humidity data. It is connected to the main unit (via RS-485 cable and power cord) and is powered and controlled by the main unit. Power is only supplied when the main unit is activated for data acquisition to save power. By applying the same voltage to both enclosed and exposed copper sections, the resistance value is obtained and input into a pre-generated corrosion model to determine the actual corrosion level and rate. See details for further information. Figure 6 .

[0160] The gateway module receives data reported by the collector, starts MQTT, HTTP, TCP services, etc., and packages the data into internal data formats according to the budget configuration, and pushes them to the corresponding protocol topic of the message queue, such as the Modbus protocol, and pushes the Modbus topic.

[0161] The protocol module is used to parse various collected and reported data, subscribe to the data of the current protocol in the message queue, parse bytes into specific values. For example, subscribing to the Modbus protocol, parsing the temperature, 0x0102, the temperature value is 25.7℃, and pushing the parsed data to the business topic of the message queue according to the internal format.

[0162] The business module processes various types of data. It consists of multiple microservices that subscribe to business topics in a message queue to obtain real-time data. Each service adds corresponding logs, which are then displayed on a visualization dashboard. The module handles tasks such as issuing alerts and notifications. For details, please refer to [link / reference]. Figure 7 and Figure 8 .

[0163] In summary, the overall architecture of this system can include three services:

[0164] (1) Gateway service: used to receive all incoming data, and to packetize, distribute, and publish it to the protocol;

[0165] (2) Protocol service: Subscribe to the corresponding protocol, parse the protocol, obtain the data, encapsulate it into a unified format, and publish it to the business;

[0166] The following are examples of some protocols:

[0167] Protocol 1, DLT645-2007:

[0168] Source data: 0x68000000000068910833333333343333337E16;

[0169] After encapsulation: {"ts": 1724729857,"data": {"electricity": 0.01}};

[0170] Protocol 2, IEC 104:

[0171] Source data: 0x681904000200240100000100020000b6f39d3f0073692e0fbc0717

[0172] After encapsulation: {"ts": 1724729857,"data": {"2": 1.234,"time": "2023-07-28 15:46:26.995+0800CST"}}

[0173] Protocol 3: Internal protocol (no parsing required, already encapsulated at the device layer)

[0174] Encapsulated data: {"ts": 1724729857,"sysdata": {"temperature": 25.6,"humidity": 56,"cpu_rate": 10.8},"data": {"fssl": 0.01,"fsd": 0.15}};

[0175] Note: The ts field is the timestamp of the data received by the server, data is remote sensing / point table data (e.g., fssl: corrosion rate, fsd: corrosion degree), and sysdata is system data (internal protocol support, information such as temperature, humidity, and CPU usage).

[0176] (3) Business services: can be divided into multiple sub-modules according to specific needs. Each sub-module subscribes to data and performs corresponding data processing (for example, the log module stores the data in the database).

[0177] In the embodiments provided in this disclosure, it should be understood that the disclosed apparatus and methods can also be implemented in other ways. The apparatus embodiments described above are merely illustrative; for example, the flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments of this disclosure. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions marked in the blocks may occur in a different order than those marked in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram and / or flowchart, and combinations of blocks in block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0178] It should be noted that, in this disclosure, 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 a process, method, article, or apparatus. Without further limitation, an element limited by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0179] While the embodiments disclosed herein are as described above, the foregoing content is merely for the purpose of facilitating understanding of this disclosure and is not intended to limit this disclosure. Any person skilled in the art to which this disclosure pertains may make any modifications and changes in form and detail of the implementation without departing from the spirit and scope of this disclosure; however, the scope of patent protection of this disclosure shall still be determined by the scope defined in the appended claims.

Claims

1. A corrosion degree monitoring device, characterized in that, include: device body; The first conductive module is disposed inside the main body of the device; The second conductive module is disposed on the outer wall of the device body; A first current sensor is disposed inside the device body and electrically connected to the first conductive module, for detecting the first current flowing through the first conductive module; The second current sensor is disposed inside the device body and electrically connected to the second conductive module, and is used to detect the second current flowing through the second conductive module; A processor, disposed inside the device body and electrically connected to the first current sensor and the second current sensor, is used to determine the degree of corrosion based on the first current and the second current. The first conductive module is disposed in an exposed manner on the outer wall of the device body, while the second conductive module is disposed in a sealed manner inside the device body.

2. The apparatus according to claim 1, characterized in that, Both the first conductive module and the second conductive module include red copper.

3. The apparatus according to claim 1, characterized in that, The processor is used to determine the degree of corrosion based on the difference between the first current and the second current using a preset corrosion model.

4. The apparatus according to claim 3, characterized in that, The preset corrosion model includes a first corrosion model, which includes: Y = dl * K1 Where Y represents the degree of corrosion; dl represents the current difference; and K1 is a constant.

5. The apparatus according to claim 3, characterized in that, The preset corrosion model includes a second corrosion model, which includes: Where Y represents the degree of corrosion; dl represents the current difference; and K2, K3, and K4 are all constants.

6. A pipeline environmental monitoring device, characterized in that, include: The environmental monitoring device body is installed on the outer wall of the inner pipe of the pipeline; The corrosion degree monitoring device according to any one of claims 1 to 5 is disposed inside the body of the environmental monitoring device and exposes the first conductive module of the corrosion degree monitoring device so that the first conductive module is in contact with the environment outside the body of the environmental monitoring device; A temperature sensor is installed inside the environmental monitoring device body to detect temperature data of the external environment of the environmental monitoring device body. A humidity sensor is installed inside the environmental monitoring device body to detect humidity data of the external environment of the environmental monitoring device body; A communication module, located inside the environmental monitoring device body, is communicatively connected to the control module and is used to receive data acquisition commands and / or provide feedback monitoring data; wherein, the monitoring data includes one or more of temperature data, humidity data, and corrosion degree; The control module is located inside the environmental monitoring device and is communicatively connected to the corrosion monitoring device, the temperature sensor, and the humidity sensor, respectively, and is used to acquire the monitoring data in response to the data acquisition command.

7. A pipeline environmental monitoring system, characterized in that, include: The pipeline environmental monitoring device as described in claim 6; The data acquisition device is electrically connected to the pipeline environmental monitoring device and is used to activate the pipeline environmental monitoring device and acquire monitoring data through the pipeline environmental monitoring device. The data processing subsystem is communicatively connected to the acquisition device and is used to analyze and process the monitoring data in order to issue an early warning when the monitoring data meets preset early warning conditions.

8. The system according to claim 7, characterized in that, The data acquisition device includes: A battery is used to provide power to the pipeline environmental monitoring device. An electrically controllable switch, one end of which is connected to the battery and the other end of which is connected to the pipeline environmental monitoring device; The data acquisition control unit is electrically connected to the electrically controllable switch and is used to issue data acquisition commands to control the electrically controllable switch to be in a closed state, thereby activating the pipeline environment monitoring device and acquiring monitoring data through the pipeline environment monitoring device.

9. The system according to claim 8, characterized in that, The data acquisition control unit issues data acquisition commands at preset time intervals.

10. The system according to claim 8, characterized in that, The data acquisition and control unit is also used to respond to a customized data request and control the pipeline environment monitoring device to feed back monitoring data corresponding to the customized data request.

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