A portable pipeline ultrasonic corrosion online monitoring and early warning device

Abstract

The present application relates to the technical fields of nondestructive testing and ultrasonic corrosion monitoring, and discloses a movable pipeline ultrasonic corrosion online monitoring and early warning device, which comprises: two annular moving frames are sleeved on a pipeline, and a moving part is arranged on the annular moving frame; a plurality of bearing cross beams are arranged between the two annular moving frames along the length direction of the pipeline, and the plurality of bearing cross beams are uniformly distributed in the circumferential direction of the pipeline; a plurality of ultrasonic probes are arranged on each bearing cross beam; a control system is used for receiving echo signals of the ultrasonic probes; a monitoring and early warning system is configured with a corrosion rate threshold value, is connected with the control system, is used for calculating pipeline wall thickness information at each position according to the received echo signals, and is used for calculating a corrosion rate according to the wall thickness information; when the corrosion rate exceeds the corrosion rate threshold value, early warning information is sent; the device realizes full-pipeline-length and full-direction online monitoring of the pipeline, and realizes real-time evaluation and automatic early warning of the corrosion state of the pipeline, thereby improving the operation safety of the in-service pipeline.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing and ultrasonic corrosion monitoring technology, and in particular to a mobile online monitoring and early warning device for ultrasonic corrosion of pipelines. Background Technology

[0002] Pipeline failure modes mainly include third-party damage, corrosion, natural disasters, equipment failure, and operational errors, among which corrosion is one of the main causes of pipeline failure. Corrosion is usually caused by chemical or electrochemical reactions between the pipeline material and the transported medium or the external environment, leading to gradual thinning of the pipe wall and ultimately affecting the safety of the pipeline structure. To ensure operational safety, pipelines must be inspected before being put into use and during service. Pre-service inspection is mainly used to assess whether the pipeline meets operational requirements during the design, manufacturing, and installation stages; while post-service inspection focuses on continuously assessing the operational status of in-service pipelines to detect potential corrosion, wear, and other potential defects as early as possible, and to take timely repair or replacement measures to avoid serious consequences from pipeline failure.

[0003] Among external inspection technologies, ultrasonic thickness measurement has been widely used in pipeline corrosion monitoring due to its fast detection speed, high sensitivity, strong penetration ability, and lack of damage to the object being measured. This technology obtains pipeline wall thickness information by measuring the propagation time of ultrasonic waves within the pipe wall, thereby achieving a quantitative assessment of the degree of corrosion and effectively identifying wall thickness variations within the pipeline and in localized areas. However, existing ultrasonic thickness measurement methods mostly rely on manual point-by-point or fixed-location inspections, making it difficult to achieve continuous monitoring of large-scale, multi-location, and full-length pipelines. Furthermore, the detection efficiency and real-time performance under complex operating conditions still need improvement.

[0004] Therefore, developing an external ultrasonic online monitoring device for pipelines that can move freely in the axial direction to achieve continuous synchronous detection of in-service pipelines with varying diameters, full length, and all directions, as well as real-time monitoring and automatic early warning of corrosion status, has become a key technology for improving the operation and maintenance safety of pipelines. Summary of the Invention

[0005] This invention proposes a mobile pipeline ultrasonic corrosion online monitoring and early warning device to address the shortcomings of the prior art. The device can move freely along the pipeline axis without disassembly, enabling full-length, all-round online monitoring of the pipeline. Combined with remote data transmission and cloud processing technology, it can perform real-time assessment and automatic early warning of pipeline corrosion status, thereby improving the operation and maintenance safety of in-service pipelines.

[0006] The technical solution of this invention is: a portable online monitoring and early warning device for ultrasonic corrosion of pipelines, used for pipeline monitoring, comprising: Two annular movable frames are fitted onto the pipe, and each of the two annular movable frames is provided with a movable part that abuts against the outer wall of the pipe; Multiple load-bearing crossbeams are arranged between the two annular movable frames along the length of the pipe, and the multiple load-bearing crossbeams are evenly distributed around the circumference of the pipe; Multiple ultrasonic probes are respectively mounted on each of the aforementioned load-bearing crossbeams; The control system is connected to each of the ultrasonic probes and is used to control each of the ultrasonic probes to emit ultrasonic pulses and receive echo signals. The monitoring and early warning system is equipped with a corrosion rate threshold, which is connected to the control system signal. It is used to calculate the wall thickness information at various points in the pipeline based on the received echo signals, and to calculate the corrosion rate based on the wall thickness information. When the calculated corrosion rate exceeds the corrosion rate threshold, an early warning message is issued.

[0007] In at least one embodiment of the present invention, the monitoring and early warning system is further used to generate a three-dimensional map of the corrosion state of the pipeline based on the wall thickness information at various points in the pipeline, and to generate a three-dimensional map of the corrosion rate at various points in the pipeline based on the corrosion rate at various points in the pipeline; the control system includes: a monitoring unit, a communication module, and a display module; the monitoring unit is signal-connected to multiple ultrasonic probes and is used to receive the echo signals from each of the ultrasonic probes; the communication module is signal-connected to the monitoring unit, the monitoring and early warning system, and the display module, and is used to send the echo signals from various points in the pipeline to the monitoring and early warning system, and to receive the three-dimensional map of the corrosion state, the three-dimensional map of the corrosion rate, and the early warning information corresponding to the ultrasonic probe positions returned by the monitoring and early warning system; the display module is used to display the three-dimensional map of the corrosion state, the three-dimensional map of the corrosion rate, and the early warning information corresponding to the ultrasonic probe positions.

[0008] In at least one embodiment of the present invention, the control system further includes a control unit. Each of the supporting beams is provided with a plurality of probe supports. Each probe support is provided with a telescopic member on the side facing the pipe. The ultrasonic probe is disposed on the movable part of the telescopic member. A pressure sensor is also provided on the probe support. The pressure sensor is used to detect the contact force between the ultrasonic probe and the pipe. Each telescopic member and the pressure sensor are signal-connected to the control unit. The control unit is used to control the telescopic member to extend and retract, and to control the telescopic member to stop extending according to the contact force.

[0009] In at least one embodiment of the present invention, each of the supports is provided with a coupling agent spraying mechanism. The coupling agent spraying mechanism includes: a storage chamber, a pressure pump and a conduit disposed in the probe support. The inlet of the pressure pump is connected to the storage chamber. One end of the conduit is connected to the outlet of the pressure pump, and the other end is located on the side of the ultrasonic probe. The pressure pump is signal connected to the control unit.

[0010] In at least one embodiment of the present invention, a plurality of movable parts are provided on the inner wall of each of the annular movable frames. The plurality of movable parts are evenly distributed around the inner wall of the annular movable frame. Each movable part includes a spring rod vertically disposed on the inner wall of the annular movable frame and a roller disposed at the movable end of the spring rod. The roller is provided with a locking structure.

[0011] In at least one embodiment of the present invention, the online monitoring and early warning system is a cloud platform, and the communication module is a wireless communication module.

[0012] In at least one embodiment of the present invention, one of the ring-shaped mobile frames is provided with a mounting box, and the monitoring unit, communication module, display module and control unit are all disposed in the mounting box.

[0013] In at least one embodiment of the present invention, the annular movable frame includes two semicircular plates, which are bolted together to form a complete circle.

[0014] Compared with the prior art, the beneficial effects of the present invention are: 1. The mobile pipeline ultrasonic corrosion online monitoring and early warning device proposed in this invention, through the setting of an axially freely movable annular moving frame and a supporting crossbeam structure, allows the device to slide continuously along the length of the pipeline without disassembly under the action of the moving part. With the cooperation of multiple circumferentially distributed ultrasonic probes, it can achieve synchronous online monitoring of the entire pipeline length and all directions, thereby overcoming the drawbacks of scattered detection points and cumbersome manual arrangement, and significantly improving detection efficiency and coverage. At the same time, with the cooperation of the control system and the monitoring and early warning system, the monitoring data can be processed quickly and early warning can be given for the location of the problem. Thus, the detection process is automated and intelligent, effectively improving the real-time performance, stability and operation and maintenance safety of corrosion monitoring of in-service pipelines.

[0015] 2. This invention, by placing each ultrasonic probe at the movable end of the telescopic component, and in cooperation with the pressure sensor and control unit, allows the ultrasonic probe to extend when the device moves to the detection position on the pipeline, so that the ultrasonic probe abuts against the outer wall of the pipeline. During the contact process between the ultrasonic probe and the pipeline, the control unit can promptly control the ultrasonic probe to stop extending and retracting based on the pressure monitoring information from the pressure sensor, thereby achieving automatic contact control between the ultrasonic probe and the outer wall of the pipeline. Furthermore, by setting a moving part composed of rollers and spring rods, this invention allows the spring rods to push the rollers to always abut against the outer wall of the pipeline during the movement of the device. The combined effect of the moving part and the automatically contactable ultrasonic probes enables the device to effectively handle in-service pipelines, improving the detection adaptability of the device.

[0016] 3. This invention, by setting up a coupling agent spraying mechanism consisting of a storage chamber, a pressure pump, and a conduit, extracts the coupling agent from the storage chamber through the pressure pump when the ultrasonic probe is ready to contact the outer wall of the pipeline for detection, and delivers it to the head of the ultrasonic probe through the conduit. This further realizes the automation and intelligence of the detection process, and effectively improves the real-time performance and stability of corrosion monitoring of in-service pipelines. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the structure of the annular movable support of the present invention; Figure 3 This is a schematic diagram of the structure of the load-bearing beam of the present invention; Figure 4 This is a schematic diagram of the probe support structure of the present invention; Figure 5 This is a schematic diagram of the electrical and communication system and control system of the present invention.

[0018] Explanation of reference numerals in the attached figures: 1. Pipeline; 2. Circular moving frame; 21. Moving part; 211. Spring rod; 212. Roller; 213. Locking structure; 3. Bearing beam; 4. Ultrasonic probe; 5. Control system; 51. Communication module; 52. Display module; 53. Mounting box; 54. Power module; 6. Probe support; 61. Telescopic component; 7. Coupling agent spraying mechanism; 71. Storage chamber; 72. Pressure pump; 73. Conduit. Detailed Implementation

[0019] The accompanying drawings in this invention are not strictly drawn to scale, and the specific dimensions and quantity of each structure can be determined according to actual needs. The drawings described in this invention are merely structural schematic diagrams.

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the described embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Unless otherwise defined, the technical or scientific terms used herein should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "inner," "outer," "upper," "lower," "far," "near," "front," and "rear" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0022] Combination Figures 1 to 5 As shown, a portable online ultrasonic corrosion monitoring and early warning device for pipeline 1 is used for monitoring pipeline 1, comprising: Two annular movable frames 2 are mounted on the pipe 1. Each of the two annular movable frames 2 is provided with a movable part 21 that abuts against the outer wall of the pipe 1. The annular movable frame 2 includes two semicircular plates, which are bolted together to form a complete circle. Multiple load-bearing crossbeams 3 are arranged between two annular movable frames 2 along the length of the pipe 1. The two ends of the load-bearing crossbeams 3 are fixedly connected to the annular movable frames 2 respectively. The multiple load-bearing crossbeams 3 are evenly distributed around the circumference of the pipe 1. Multiple ultrasonic probes 4 are respectively installed on each supporting crossbeam 3, and the multiple ultrasonic probes 4 are evenly distributed on the supporting crossbeam 3; The control system 5 is connected to each ultrasonic probe 4 via signal connection, and is used to control each ultrasonic probe 4 to emit ultrasonic pulses and receive echo signals. The monitoring and early warning system is equipped with a corrosion rate threshold and is connected to the control system 5 signal. It is used to calculate the wall thickness information at various points in the pipeline based on the received echo signals, and to calculate the corrosion rate based on the wall thickness information. When the calculated corrosion rate exceeds the corrosion rate threshold, an early warning message is issued.

[0023] As an alternative embodiment, the monitoring and early warning system is also used to generate a three-dimensional map of the corrosion state of the pipeline 1 based on the wall thickness information at various locations of the pipeline 1, and to generate a three-dimensional map of the corrosion rate at various locations of the pipeline 1 based on the corrosion rate at various locations of the pipeline 1. The control system 5 includes: a monitoring unit, a communication module 51, and a display module 52. The monitoring unit is signal-connected to multiple ultrasonic probes 4 and is used to receive the echo signals from each ultrasonic probe 4. The communication module 51 is signal-connected to the monitoring unit, the monitoring and early warning system, and the display module 52 and is used to send the echo signals from various locations of the pipeline 1 to the monitoring and early warning system, and to receive the three-dimensional map of the corrosion state, the three-dimensional map of the corrosion rate, and the early warning information corresponding to the location of the ultrasonic probe 4 returned by the monitoring and early warning system. The display module 52 is used to display the three-dimensional map of the corrosion state, the three-dimensional map of the corrosion rate, and the early warning information corresponding to the location of the ultrasonic probe 4. Monitoring personnel can promptly learn about the corrosion status of the pipeline 1 on the display module 52 based on the feedback information.

[0024] As an alternative embodiment, such as Figure 3 As shown, the control system 5 also includes a control unit. Each load-bearing beam 3 is equipped with multiple probe supports 6. Each probe support 6 has a telescopic component 61 on the side facing the pipe 1. The ultrasonic probe 4 is located on the movable part of the telescopic component 61. A pressure sensor is also provided on the probe support 6. The pressure sensor is used to detect the contact force between the ultrasonic probe 4 and the pipe 1. Each telescopic component 61 and the pressure sensor are connected to the control unit. The control unit is used to control the extension and retraction of the telescopic component 61 and to control the telescopic component 61 to stop extending according to the contact force. Specifically, each load-bearing beam 3 is equipped with four probe supports 6. The probe support 6 is a rectangular shell structure, and the telescopic component 61 is an electric telescopic rod. The configuration of the pressure sensor ensures that the ultrasonic probe 4 fits stably and avoids damage to the surface of the pipe 1.

[0025] As an alternative embodiment, each probe support 6 is equipped with a coupling agent spraying mechanism 7. The coupling agent spraying mechanism 7 includes: a storage chamber 71, a pressure pump 72, and a conduit 73 disposed in the probe support 6. The inlet of the pressure pump 72 is connected to the storage chamber 71, one end of the conduit 73 is connected to the outlet of the pressure pump 72, and the other end is located on the side of the ultrasonic probe 4. The pressure pump 72 is signal-connected to the control unit. Furthermore, the storage chamber 71 can also be equipped with an air pump or a pressurizing device to replace the pressure pump 72. When the storage chamber 71 is sealed, the coupling agent is output by pressure, realizing automatic spraying of the coupling agent after movement or repositioning.

[0026] As an alternative embodiment, such as Figure 2As shown, each annular movable frame 2 has multiple movable parts 21 on its inner wall, which are evenly distributed circumferentially on the inner wall of the annular movable frame 2. Each movable part 21 includes a spring rod 211 vertically mounted on the inner wall of the annular movable frame 2 and a roller 212 mounted on the movable end of the spring rod 211. The roller 212 is equipped with a locking structure 213. Specifically, each annular movable frame 2 has four rollers 212. The spring rod 211 can slide radially to adapt to pipes 1 of different diameters. The locking structure 213 fixes the position of the rollers 212 after adjustment, ensuring stable operation of the device. The rollers 212 can move axially along the pipe, enabling continuous sliding of the device on the surface of the pipe 1 without disassembly or reassembly.

[0027] As an alternative embodiment, the online monitoring and early warning system is a cloud platform, and the communication module 51 is a wireless communication module that can upload the measured pipe wall thickness data to the cloud monitoring platform in real time, and receive the corrosion rate and early warning information processed by the cloud, so as to realize remote monitoring.

[0028] As an alternative embodiment, one of the annular mobile frames 2 is equipped with a mounting box 53. The monitoring unit, communication module 51, display module 52, and control unit are all housed within the mounting box 53. The mounting box 53 also contains a power supply module 54 to power the various components of the device. The display module 52 is an LCD screen used to display the probe locations where the corrosion rate exceeds a preset threshold and the corresponding corrosion rate. The online monitoring and early warning system is deployed on a cloud platform, receives and processes wall thickness data, generates a three-dimensional pipeline corrosion status map, automatically issues early warnings for severely corroded areas, and feeds the information back to maintenance personnel.

[0029] The beneficial effects of this invention are as follows: The invention utilizes an axially movable annular frame 2, enabling the ultrasonic corrosion monitoring device to operate continuously along the entire pipe length without disassembly and reassembly. This overcomes the problems of scattered detection points and cumbersome manual arrangement in existing technologies, significantly improving detection efficiency and coverage. The annular frame 2 in the movable support structure, in conjunction with the adjustable moving part 21, can be radially adjusted according to the diameter of the pipe 1, making the device suitable for in-service pipes 1 of different diameters, reducing equipment customization and replacement costs, and enhancing the device's versatility and applicability. By arranging an array of ultrasonic probes 4 on the support beam 3, synchronous online monitoring of multiple areas of the pipe 1 is achieved, avoiding the problem that traditional single-point or fixed-position detection cannot reflect corrosion distribution characteristics, thus improving corrosion assessment accuracy. Through the telescopic component 61 and pressure sensor, automatic contact and pressure feedback control of the ultrasonic probes 4 are achieved, facilitating the ultrasonic probes 4 to detach from the pipe 1 during device movement and re-attach to the pipe 1 after repositioning, effectively improving detection convenience and stability. The coupling agent spraying mechanism 7 automatically sprays coupling agent onto the surface of the ultrasonic probes 4 after device movement or repositioning, reducing manual operation. The data collected by the device is transmitted remotely and processed in the cloud to achieve intelligent monitoring and early warning of the corrosion status of in-service pipeline 1. By integrating the power supply module 54, monitoring unit, display module 52 and cloud early warning system, it can operate stably for a long time, reduce the frequency of manual inspections, provide reliable data support for the operation and maintenance of pipeline 1, help realize early detection and preventive maintenance of pipeline 1 corrosion, and significantly improve the operation and maintenance safety of pipeline 1.

[0030] The above embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit them. The protection scope of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions implemented in the present invention, and should all be covered within the protection scope of the present invention.

Claims

1. A portable online ultrasonic corrosion monitoring and early warning device for pipelines, characterized in that, include: Two annular movable frames are fitted onto the pipe, and each of the two annular movable frames is provided with a movable part that abuts against the outer wall of the pipe; Multiple load-bearing crossbeams are arranged between the two annular movable frames along the length of the pipe, and the multiple load-bearing crossbeams are evenly distributed around the circumference of the pipe; Multiple ultrasonic probes are respectively mounted on each of the aforementioned load-bearing crossbeams; The control system is connected to each of the ultrasonic probes and is used to control each of the ultrasonic probes to emit ultrasonic pulses and receive echo signals. The monitoring and early warning system is equipped with a corrosion rate threshold and is connected to the control system signal. It is used to calculate the wall thickness information at various points in the pipeline based on the received echo signals, and to calculate the corrosion rate based on the wall thickness information. When the calculated corrosion rate exceeds the corrosion rate threshold, an early warning message is issued.

2. The portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 1, characterized in that, The monitoring and early warning system is also used to generate a three-dimensional map of the pipeline corrosion state based on the wall thickness information at various points in the pipeline, and to generate a three-dimensional map of the corrosion rate at various points in the pipeline based on the corrosion rate at various points in the pipeline. The control system includes a monitoring unit, a communication module, and a display module. The monitoring unit is connected to multiple ultrasonic probes and is used to receive the echo signals from each of the ultrasonic probes. The communication module is connected to the monitoring unit, the monitoring and early warning system, and the display module and is used to send the echo signals from various points in the pipeline to the monitoring and early warning system, and to receive the three-dimensional map of the corrosion state, the three-dimensional map of the corrosion rate, and the early warning information corresponding to the ultrasonic probe positions returned by the monitoring and early warning system. The display module is used to display the three-dimensional map of the corrosion state, the three-dimensional map of the corrosion rate, and the early warning information corresponding to the ultrasonic probe positions.

3. The portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 1, characterized in that, The control system also includes a control unit. Each of the load-bearing beams is provided with multiple probe supports. Each probe support has a telescopic component on the side facing the pipe. The ultrasonic probe is located in the movable part of the telescopic component. The probe support is also provided with a pressure sensor. The pressure sensor is used to detect the contact force between the ultrasonic probe and the pipe. Each telescopic component and the pressure sensor are connected to the control unit. The control unit is used to control the telescopic component to extend and retract, and to control the telescopic component to stop extending based on the contact force.

4. The portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 3, characterized in that, Each of the aforementioned probe supports is equipped with a coupling agent spraying mechanism, which includes: a storage chamber, a pressure pump, and a conduit disposed within the probe support. The inlet of the pressure pump is connected to the storage chamber, one end of the conduit is connected to the outlet of the pressure pump, and the other end is located on the side of the ultrasonic probe. The pressure pump is signal-connected to the control unit.

5. A portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 1, characterized in that, Each of the aforementioned annular movable frames has multiple movable parts on its inner wall, which are evenly distributed around the inner wall of the annular movable frame. Each movable part includes a spring rod vertically disposed on the inner wall of the annular movable frame and a roller disposed at the movable end of the spring rod. The roller is equipped with a locking structure.

6. A portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 2, characterized in that, The online monitoring and early warning system is a cloud platform, and the communication module is a wireless communication module.

7. A portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 2, characterized in that, One of the ring-shaped mobile frames is equipped with a mounting box, and the monitoring unit, communication module, display module and control unit are all installed inside the mounting box.

8. A portable pipeline ultrasonic corrosion online monitoring and early warning device as described in claim 1, characterized in that, The annular movable frame includes two semicircular plates, which are bolted together to form a complete circle.

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