A pipeline coating integrity monitoring system and method

Abstract

The application relates to the technical field of pipeline monitoring, and discloses a pipeline coating integrity monitoring system and method, which comprises a data acquisition module; the data acquisition module comprises a sensor array unit; the sensor array unit is provided with passive sensors arranged on the surface of a pipeline coating; the passive sensors comprise electrochemical sensors, temperature sensors and humidity sensors; the sensor array unit is configured to acquire a pipeline coating surface current value, a pipeline coating surface potential value through the electrochemical sensors, a pipeline coating surface temperature value through the temperature sensors and a pipeline coating environment humidity value through the humidity sensors. The application can improve the detection efficiency based on the passive sensors, the wireless sensors are easy to maintain, the data real-time performance is high, and the application can adapt to harsh environments.

Description

Technical Field

[0001] This application relates to the field of pipeline monitoring technology, and more specifically, to a pipeline coating integrity monitoring system and method. Background Technology

[0002] With the widespread application of large-scale pipelines in industries such as oil, natural gas, and chemicals, pipeline corrosion and coating aging have gradually become important factors affecting pipeline safety and operational efficiency. Pipeline coatings play a crucial role in corrosion prevention and extending pipeline service life; however, aging and corrosion of the coating are inevitable during long-term operation, especially in extreme environments where coating performance gradually declines, leading to accelerated pipeline corrosion and even leaks.

[0003] Existing pipeline coating monitoring systems are typically active sensor systems. These systems often utilize electrochemical, temperature, and humidity sensors, requiring external power supplies. Data loss or sensor failure can occur due to battery life issues or power supply problems.

[0004] While existing sensors can acquire some monitoring data, they face challenges related to wireless transmission and battery replacement, leading to significant maintenance and management difficulties and reduced reliability. Therefore, existing technologies suffer from high maintenance costs, poor data real-time performance, poor environmental adaptability, low detection efficiency, and low detection accuracy. Summary of the Invention

[0005] In view of this, this application proposes a pipeline coating integrity monitoring system and method, aiming to solve the problems of high maintenance cost, poor data real-time performance, poor environmental adaptability, low detection efficiency, and low detection accuracy in the current technology.

[0006] In a first aspect, this application proposes a pipeline coating integrity monitoring system, comprising: a data acquisition module; the data acquisition module comprising: a sensor array unit; the sensor array unit being provided with passive sensors arranged on the surface of the pipeline coating; the passive sensors comprising: an electrochemical sensor, a temperature sensor, and a humidity sensor; the sensor array unit being configured to acquire the surface current value and surface potential value of the pipeline coating through the electrochemical sensor, acquire the surface temperature value of the pipeline coating through the temperature sensor, and acquire the ambient humidity value of the pipeline coating through the humidity sensor.

[0007] Optionally, the data acquisition module further includes: a transmission unit; the transmission unit is equipped with sensor nodes arranged around the electrochemical sensor, temperature sensor, and humidity sensor; the transmission unit is communicatively connected to the sensor array unit; the transmission unit is configured to transmit the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module through the sensor nodes.

[0008] Optionally, the system further includes: a data processing module; the data processing module includes: a preprocessing unit, a storage unit, a data analysis unit, a prediction unit, an evaluation unit, and an early warning alarm unit; the preprocessing unit is communicatively connected to the transmission unit; the storage unit is communicatively connected to the preprocessing unit, the data analysis unit, the prediction unit, the evaluation unit, and the early warning alarm unit respectively; the data analysis unit is communicatively connected to the prediction unit; the early warning alarm unit is communicatively connected to the prediction unit and the evaluation unit respectively; the preprocessing unit is configured to read the pipe coating surface current value, pipe coating surface potential value, pipe coating surface temperature value, and pipe coating ambient humidity value from the transmission unit, and preprocess the pipe coating surface current value, pipe coating surface potential value, pipe coating surface temperature value, and pipe coating ambient humidity value respectively to obtain the first pipe coating surface current value, the first pipe coating surface potential value, the first pipe coating surface temperature value, and the first pipe coating ambient humidity value; the storage unit is configured to store the first pipe coating surface current value, the first pipe coating surface potential value, the first pipe coating surface temperature value, the first pipe coating ambient humidity value, and the first historical... The system includes a corrosion trend, a second historical corrosion trend, and a historical aging trend. A data analysis unit is configured to determine the corrosion rate and degree of corrosion of the pipeline coating based on the first pipeline coating's ambient humidity, surface current, and surface potential. The data analysis unit is also configured to determine the aging degree of the pipeline coating based on the first pipeline coating's surface temperature. A prediction unit is configured to determine the corrosion trend of the first and second coatings based on the corrosion rate and degree of corrosion. The prediction unit is also configured to determine the aging trend of the pipeline coating based on its aging degree. An evaluation unit is configured to perform a weighted summation of the first pipeline coating's surface current, surface potential, surface temperature, and ambient humidity to determine the pipeline coating's health index. An early warning alarm unit is configured to determine whether an early warning is needed based on the first coating corrosion trend, the second coating corrosion trend, the pipeline coating aging trend, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend. The early warning alarm unit is also configured to determine whether an alarm is needed based on the pipeline coating's health index and a health index threshold.

[0009] Optionally, the electrochemical sensor, temperature sensor, and humidity sensor are all equipped with radio frequency identification (RFID) chips.

[0010] Optionally, the sensor node consists of a passive RFID tag receiver and a wireless communication unit. When the sensor node transmits the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module, the process includes: the signal generated by the sensor node triggers the RFID chip in the electrochemical sensor, the RFID chip in the temperature sensor, and the RFID chip in the humidity sensor, respectively, to transmit the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating measured by the electrochemical sensor to the sensor node; the sensor node then transmits the surface current value, surface potential value, surface temperature value, and ambient humidity value to the data processing module.

[0011] Optionally, when reading the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating from the transmission unit, and preprocessing the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating respectively, the process includes: reading the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating from the transmission unit, and applying Kalman filtering to each of the surface current value, surface potential value, surface temperature value, and ambient humidity value for noise reduction; the first surface current value of the pipe coating satisfies the following formula:

[0012]

[0013] Where I(t) is the surface current value of the pipe coating, and K(t) is the Kalman gain. The predicted surface current value of the pipe coating. The surface current value of the first pipe coating; the surface potential value of the first pipe coating satisfies the following formula:

[0014]

[0015] Where V(t) is the surface potential value of the pipe coating. The predicted surface potential value of the pipe coating. The surface potential value of the first pipe coating; the surface temperature value of the first pipe coating satisfies the following formula:

[0016]

[0017] Where T(t) is the surface temperature of the pipe coating. The predicted surface temperature of the pipe coating. The surface temperature of the first pipe coating; the ambient humidity of the first pipe coating satisfies the following formula:

[0018]

[0019] Where H(t) is the ambient humidity value of the pipe coating, The predicted ambient humidity value for the pipe coating. The humidity value represents the ambient humidity of the first pipe coating.

[0020] Optionally, when determining the corrosion rate and degree of corrosion of the pipe coating based on the ambient humidity value, surface current value, and surface potential value of the first pipe coating, the method includes: determining the corrosion rate of the first pipe coating based on the surface current value; the corrosion rate of the first pipe coating satisfies the following formula:

[0021]

[0022] Where n is the charge transfer number, F is the Faraday constant, A is the area of ​​the electrode, and R... corr (t) represents the corrosion rate of the first pipeline coating; the corrosion rate of the first pipeline coating is corrected based on the ambient humidity value to obtain the final pipeline coating corrosion rate; the pipeline coating corrosion rate satisfies the following formula:

[0023]

[0024] Where, k H R is the temperature correction factor. corr′ (t) represents the corrosion rate of the pipe coating; the degree of corrosion is determined based on the surface potential value of the first pipe coating; the degree of corrosion satisfies the following formula:

[0025]

[0026] Among them, C corr (t) represents the degree of corrosion, k1 is the first empirical coefficient, k2 is the second empirical coefficient, and V corr The potential value is given under stable corrosion conditions, where T is temperature and R is the gas constant.

[0027] Optionally, determining the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating includes: determining the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating; the degree of aging of the pipe coating satisfies the following formula:

[0028]

[0029] Among them, A age (t) represents the aging degree of the pipe coating, A0 is the pre-factor, and E a To activate energy.

[0030] Optionally, the corrosion tendency of the first coating satisfies the following formula:

[0031]

[0032] Among them, T corr1 (t) represents the corrosion tendency of the first coating; the corrosion tendency of the second coating satisfies the following formula:

[0033]

[0034] Among them, T corr2 (t) represents the corrosion trend of the second coating; the aging trend of the pipeline coating satisfies the following formula:

[0035]

[0036] Among them, T age (t) represents the aging trend of the pipeline coating.

[0037] Optionally, the health index of the pipe coating satisfies the following formula:

[0038]

[0039] Wherein, CHI is the pipe coating health index, w1 is the first weighting factor, w2 is the second weighting factor, w3 is the third weighting factor, and w4 is the fourth weighting factor.

[0040] Optionally, when determining whether an early warning is needed based on the corrosion trend of the first coating, the corrosion trend of the second coating, the aging trend of the pipeline coating, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend, the following steps are taken: If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a Level 1 early warning is issued; if the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is greater than the historical aging trend, then a Level 2 early warning is issued; if the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a Level 3 early warning is issued; if the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a Level 4 early warning is issued.

[0041] Optionally, when determining whether an alarm is needed based on the pipeline coating health index and the health index threshold, the following applies: if the pipeline coating health index is less than the health index threshold, an alarm is triggered; if the pipeline health index is greater than or equal to the health index threshold, no alarm is triggered.

[0042] Optionally, the data processing module also includes a visualization unit, which is communicatively connected to the storage unit, prediction unit, evaluation unit, and early warning alarm unit; the visualization unit is configured to display data.

[0043] Secondly, a method for monitoring the integrity of a pipeline coating is provided, applied to the pipeline coating integrity monitoring system described in the first aspect. The method includes: acquiring surface current values, surface potential values, surface temperature values, and ambient humidity values ​​of the pipeline coating; preprocessing the surface current values, surface potential values, surface temperature values, and ambient humidity values ​​of the pipeline coating to obtain first surface current values, first surface potential values, first surface temperature values, and first ambient humidity values ​​of the pipeline coating; and determining pipeline coating corrosion based on the first ambient humidity values, first surface current values, and first surface potential values ​​of the pipeline coating. The corrosion rate and degree of corrosion are determined; the aging degree of the pipe coating is determined based on the surface temperature value of the first pipe coating; the corrosion trend of the first coating and the corrosion trend of the second coating are determined based on the corrosion rate and degree of corrosion of the pipe coating; the aging trend of the pipe coating is determined based on the aging degree of the pipe coating; the health index of the pipe coating is determined by weighted summation of the surface current value, surface potential value, surface temperature value, and ambient humidity value of the first pipe coating; the corrosion trend of the first coating, the corrosion trend of the second coating, the aging trend of the pipe coating, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend; and the health index and health index threshold are used to determine whether an alarm is needed.

[0044] Thirdly, a pipeline coating integrity monitoring device is provided, including a memory and a processor; the memory is used to store computer execution instructions, and the processor is connected to the memory via a bus; when the pipeline coating integrity monitoring device is running, the processor executes the computer execution instructions stored in the memory, so that the pipeline coating integrity monitoring device performs the pipeline coating integrity monitoring method described in the second aspect.

[0045] The pipeline coating integrity monitoring device can be a network device or a component of a network device, such as a chip system within the network device. This chip system supports the network device in implementing the functions involved in the first aspect and any of its possible implementations, such as acquiring, determining, and transmitting the data and / or information involved in the aforementioned pipeline coating integrity monitoring method. The chip system includes a chip and may also include other discrete devices or circuit structures.

[0046] Fourthly, a computer-readable storage medium is provided, comprising computer-executable instructions that, when executed on a computer, cause the computer to perform the pipe coating integrity monitoring method described in the second aspect.

[0047] Fifthly, a computer program product is also provided, which includes computer instructions that, when executed on a pipe coating integrity monitoring device, cause the pipe coating integrity monitoring device to perform the pipe coating integrity monitoring method as described in the second aspect above.

[0048] It should be noted that the aforementioned computer instructions may be stored, in whole or in part, on a computer-readable storage medium. This computer-readable storage medium may be packaged together with the processor of the pipeline coating integrity monitoring device, or it may be packaged separately from the processor of the pipeline coating integrity monitoring device; this application embodiment does not limit this.

[0049] The descriptions of the second, third, fourth, and fifth aspects of this application can be referenced to the detailed description of the first aspect.

[0050] In the embodiments of this application, the name of the aforementioned pipeline coating integrity monitoring device does not limit the device or functional module itself. In actual implementation, these devices or functional modules may appear under other names. For example, the receiving unit may also be called a receiving module, receiver, etc. As long as the function of each device or functional module is similar to that of this application, it falls within the scope of the claims of this application and its equivalents.

[0051] This application provides a pipeline coating integrity monitoring system that employs a passive sensor (also known as a wireless passive sensor). This sensor does not rely on an external power source or battery, but can harvest energy through electromagnetic fields or radio frequency signals, reducing reliance on battery replacement and avoiding monitoring interruptions due to battery aging or failure. The passive sensor can operate stably for extended periods without requiring a maintenance power supply, reducing maintenance costs and complexity, and is suitable for monitoring tasks in inaccessible and harsh environments such as pipelines. Attached Figure Description

[0052] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0053] Figure 1 This is a schematic diagram of the structure of a pipeline coating integrity monitoring system provided in an embodiment of this application;

[0054] Figure 2 A schematic diagram of the structure of another pipeline coating integrity monitoring system provided in this application embodiment;

[0055] Figure 3 A schematic flowchart illustrating a pipeline coating integrity monitoring method provided in this application embodiment;

[0056] Figure 4 This is a schematic diagram of a pipe coating integrity monitoring device provided in an embodiment of this application. Detailed Implementation

[0057] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0058] As described in the background section, with the widespread application of large-scale pipelines in industries such as oil, natural gas, and chemicals, pipeline corrosion and coating aging have gradually become important factors affecting pipeline safety and operational efficiency. Pipeline coatings play a crucial role in corrosion prevention and extending pipeline service life; however, aging and corrosion of the coating are inevitable during long-term operation, especially in extreme environments where coating performance gradually declines, leading to accelerated pipeline corrosion and even leakage accidents.

[0059] Existing pipeline coating monitoring systems are typically active sensor systems. These systems often utilize electrochemical, temperature, and humidity sensors, requiring external power supplies. Data loss or sensor failure can occur due to battery life issues or power supply problems.

[0060] Moreover, existing pipeline coating monitoring methods mainly rely on manual inspection and local sampling tests. This method is not only labor-intensive and inefficient, but also cannot achieve real-time monitoring and poses significant safety hazards.

[0061] As shown above, although existing sensors can acquire some monitoring data, they face challenges related to wireless transmission and battery replacement, leading to significant difficulties in maintaining and managing the monitoring system and reducing its reliability. Therefore, existing technologies suffer from high maintenance costs, poor data real-time performance, poor environmental adaptability, low detection efficiency, and low detection accuracy.

[0062] In some embodiments of this application, such as Figure 1 As shown in the figure, this application provides a pipeline coating integrity monitoring system, which includes a data acquisition module.

[0063] The data acquisition module includes: a sensor array unit.

[0064] The sensor array unit is equipped with passive sensors arranged on the surface of the pipe coating.

[0065] Passive sensors include: electrochemical sensors, temperature sensors, and humidity sensors.

[0066] The sensor array unit is configured to acquire the surface current value and surface potential value of the pipe coating through an electrochemical sensor, the surface temperature value of the pipe coating through a temperature sensor, and the ambient humidity value of the pipe coating through a humidity sensor.

[0067] In some embodiments, the data acquisition module further includes a transmission unit.

[0068] The transmission unit is equipped with sensor nodes arranged around the electrochemical sensor, temperature sensor, and humidity sensor.

[0069] The transmission unit is communicatively connected to the sensor array unit.

[0070] The transmission unit is configured to transmit the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module via the sensor node.

[0071] In some embodiments of this application, combined with Figure 1 ,like Figure 2 As shown, the pipeline coating integrity monitoring system also includes a data processing module. The data processing module includes a preprocessing unit, a storage unit, a data analysis unit, a prediction unit, an evaluation unit, and an early warning alarm unit.

[0072] The preprocessing unit is communicatively connected to the transmission unit.

[0073] The storage unit is communicatively connected to the preprocessing unit, data analysis unit, prediction unit, evaluation unit, and early warning alarm unit.

[0074] The data analysis unit is communicatively connected to the prediction unit. The early warning and alarm unit is communicatively connected to both the prediction unit and the evaluation unit.

[0075] The preprocessing unit is configured to read the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating from the transmission unit, and preprocess the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to obtain the first surface current value, the first surface potential value, the first surface temperature value, and the first ambient humidity value of the pipe coating.

[0076] The storage unit is configured to store the surface current value of the first pipe coating, the surface potential value of the first pipe coating, the surface temperature value of the first pipe coating, the ambient humidity value of the first pipe coating, as well as the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend.

[0077] The data analysis unit is configured to determine the corrosion rate and degree of corrosion of the pipe coating based on the ambient humidity value, surface current value, and surface potential value of the first pipe coating. The data analysis unit is also configured to determine the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating.

[0078] The prediction unit is configured to determine the corrosion trend of the first coating and the corrosion trend of the second coating based on the corrosion rate and degree of corrosion of the pipeline coating. The prediction unit is also configured to determine the aging trend of the pipeline coating based on the degree of aging of the pipeline coating.

[0079] The evaluation unit is configured to perform a weighted summation of the surface current value, surface potential value, surface temperature value, and ambient humidity value of the first pipe coating to determine the pipe coating health index.

[0080] The early warning alarm unit is configured to determine whether an early warning is needed based on the corrosion trends of the first coating, the second coating, the aging trend of the pipeline coating, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend. The early warning alarm unit is also configured to determine whether an alarm is needed based on the pipeline coating health index and a health index threshold.

[0081] In some embodiments, the electrochemical sensor, temperature sensor, and humidity sensor are all equipped with RFID chips.

[0082] It should be noted that passive sensors with built-in RFID chips do not require built-in batteries; their power comes from external radio frequency signals. Thus, the pipeline coating integrity monitoring system provided in this application overcomes the shortcomings of traditional active sensors, such as short battery life and the need for frequent replacements, making it suitable for long-term deployment in difficult-to-access and complex environments like pipelines. Furthermore, passive sensors offer higher durability and stability, enabling continuous operation in harsh environments (such as high temperature, high humidity, and corrosive gases), reducing equipment failure and maintenance frequency.

[0083] In some embodiments, the sensor node consists of a passive RFID tag receiver and a wireless communication unit.

[0084] When transmitting the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module via sensor nodes, the following is included:

[0085] The signals generated by the sensor node trigger the RFID chips in the electrochemical sensor, the temperature sensor, and the humidity sensor, respectively, to transmit the surface current value and surface potential value of the pipe coating measured by the electrochemical sensor to the sensor node, the surface temperature value of the pipe coating measured by the temperature sensor to the sensor node, and the ambient humidity value of the pipe coating measured by the humidity sensor to the sensor node.

[0086] The sensing node transmits the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module.

[0087] Specifically, firstly, the sensor nodes provide the necessary power to activate the built-in electrochemical, temperature, and humidity sensors. Data exchange between the sensor nodes and these sensors occurs via short-range communication protocols (e.g., Inter-Integrated Circuit (I2C) or Serial Peripheral Interface (SPI)). Each sensor measures the current, potential, temperature, and humidity data on the pipe coating surface and transmits this data to the data processing module in real time via a wireless communication unit. During data transmission, low-power communication protocols can be applied, typically using low-power wide-area network technologies (e.g., ZigBee, LoRa, or Narrow Band Internet of Things (NB-IoT)) to ensure long-distance data transmission and long-term stable operation of the system, extending the device's lifespan.

[0088] In some embodiments, when reading the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating from the transmission unit, and preprocessing the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating respectively, the process includes:

[0089] The surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating are read from the transmission unit, and Kalman filtering is applied to the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating for noise reduction.

[0090] The surface current value of the first pipe coating satisfies the following formula:

[0091]

[0092] Where I(t) is the surface current value of the pipe coating, and K(t) is the Kalman gain. The predicted surface current value of the pipe coating. The current value on the surface of the first pipe coating.

[0093] The surface potential value of the first pipe coating satisfies the following formula:

[0094]

[0095] Where V(t) is the surface potential value of the pipe coating. The predicted surface potential value of the pipe coating. This is the surface potential value of the first pipe coating.

[0096] The surface temperature of the first pipe coating satisfies the following formula:

[0097]

[0098] Where T(t) is the surface temperature of the pipe coating. The predicted surface temperature of the pipe coating. This is the surface temperature value of the first pipe coating.

[0099] The ambient humidity value of the first pipe coating satisfies the following formula:

[0100]

[0101] Where H(t) is the ambient humidity value of the pipe coating, The predicted ambient humidity value for the pipe coating. The humidity value represents the ambient humidity of the first pipe coating.

[0102] In this embodiment of the application, in order to ensure the accuracy and reliability of the data, after reading the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating in the transmission unit.

[0103] Specifically, the Kalman filter algorithm is used to smooth each data point collected by the passive sensor, removing invalid fluctuations introduced by factors such as environmental noise, electromagnetic interference, or sensor errors, thereby obtaining more accurate pipe coating status parameters.

[0104] It should be noted that Kalman filtering can dynamically adjust estimates based on the system model and measured values, avoiding the impact of passive sensor noise or external interference on data quality, thereby improving data accuracy and reliability. Kalman filtering is a recursive filtering method that can process data in real time during system operation without waiting for all data to arrive. This makes the system highly efficient in real-time monitoring, reduces latency, and is suitable for monitoring systems operating for extended periods. The denoised data can more clearly reflect the true state of the pipeline coating, reducing interference from errors, thus providing a more reliable basis for subsequent data analysis, trend prediction, and corrosion assessment.

[0105] In some embodiments, when determining the corrosion rate and degree of corrosion of the pipe coating based on the ambient humidity value, the surface current value, and the surface potential value of the first pipe coating, the following methods are included:

[0106] The corrosion rate of the first pipe coating is determined based on the surface current value of the first pipe coating; the corrosion rate of the first pipe coating satisfies the following formula:

[0107]

[0108] Where n is the charge transfer number, F is the Faraday constant, A is the area of ​​the electrode, and R... corr (t) represents the corrosion rate of the first pipeline coating.

[0109] The corrosion rate of the first pipeline coating is corrected based on the ambient humidity value to obtain the pipeline coating corrosion rate; the pipeline coating corrosion rate satisfies the following formula:

[0110]

[0111] Where, k H R is the temperature correction factor. corr′ (t) represents the corrosion rate of the pipeline coating.

[0112] The degree of corrosion is determined based on the surface potential value of the coating on the first pipe; the degree of corrosion satisfies the following formula:

[0113]

[0114] Among them, C corr (t) represents the degree of corrosion, k1 is the first empirical coefficient, k2 is the second empirical coefficient, and V corr The potential value is given under stable corrosion conditions, where T is temperature and R is the gas constant.

[0115] In some embodiments, determining the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating includes:

[0116] The degree of aging of the pipe coating is determined based on the surface temperature of the first pipe coating; the degree of aging of the pipe coating satisfies the following formula:

[0117]

[0118] Among them, A age (t) represents the aging degree of the pipe coating, A0 is the pre-factor, and E a To activate energy.

[0119] In some embodiments, the corrosion tendency of the first coating satisfies the following formula:

[0120]

[0121] Among them, T corr1 (t) represents the corrosion trend of the first coating.

[0122] The corrosion tendency of the second coating satisfies the following formula:

[0123]

[0124] Among them, T corr2 (t) represents the corrosion trend of the second coating.

[0125] The aging trend of pipe coatings conforms to the following formula:

[0126]

[0127] Among them, T age (t) represents the aging trend of the pipeline coating.

[0128] It should be noted that the magnitude of the current reflects the intensity of the electrochemical reaction between the pipe coating and the external environment (such as water and oxygen), thus affecting the corrosion rate. Therefore, this application can preliminarily estimate the corrosion rate of the pipe coating by measuring the current value on the coating surface. Generally, the corrosion rate is positively correlated with the current value; the higher the current, the higher the corrosion rate. Ambient humidity is an important factor affecting coating corrosion; higher humidity can accelerate the hydration of the coating, thereby increasing the coating's conductivity and corrosion rate. Therefore, this application introduces the ambient humidity value of the first pipe coating to correct the corrosion rate, in order to more accurately reflect the actual corrosion state of the coating under different environmental conditions.

[0129] The pre-factor is a parameter related to material properties. Specifically, it can be determined by fitting the theoretical model used (e.g., the Arrhenius equation, the Eyring rate equation, or an electrochemical kinetic model).

[0130] First, the reaction rate or corrosion rate is determined under controlled variables (such as temperature, pressure, or potential); then, the equation is linearized (e.g., logarithmically) using the experimental data to separate A0.

[0131] For example, in corrosion experiments, the relationship between the corrosion rate k and temperature is measured, and then combined with the Arrhenius equation. Plot ln(k) against 1 / T and calculate A0 using the intercept.

[0132] It should be noted that relying solely on a single parameter (such as current or potential) may not fully reflect the corrosion situation. Considering multiple factors together can improve the accuracy and reliability of corrosion assessment. Temperature monitoring allows for real-time evaluation of the aging degree of the pipeline coating, especially in high-temperature environments where the coating aging rate may accelerate, thus affecting its anti-corrosion effect. The introduction of temperature data helps provide a reference for pipeline maintenance cycles and repair plans. Therefore, this application, by combining the current value of the coating surface with ambient humidity, can more accurately predict the corrosion rate, avoiding errors caused by single factors and ensuring that the corrosion rate calculation is more consistent with reality. By combining current, humidity, and potential values, the degree of corrosion of the pipeline coating can be analyzed from multiple angles and in a comprehensive manner.

[0133] In some embodiments, the pipe coating health index satisfies the following formula:

[0134]

[0135] Wherein, CHI is the pipe coating health index, w1 is the first weighting factor, w2 is the second weighting factor, w3 is the third weighting factor, and w4 is the fourth weighting factor.

[0136] It should be noted that in all the above formulas, t and t-1 both represent time, and their units are the same.

[0137] In some embodiments, determining whether an early warning is needed based on the corrosion trend of the first coating, the corrosion trend of the second coating, the aging trend of the pipeline coating, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend includes:

[0138] If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level one warning will be issued.

[0139] If the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is greater than the historical aging trend, then a level two warning will be issued.

[0140] If the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level three warning will be issued.

[0141] If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level four warning will be issued.

[0142] Specifically, when the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, although the corrosion trend of the first coating has increased, indicating accelerated corrosion, the corrosion trend of the second coating has slowed down, and the aging trend of the pipeline coating is relatively stable. Despite some changes in coating corrosion, the stable aging situation indicates that initial attention should be paid and a level one warning should be issued.

[0143] When the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is greater than the historical aging trend, the corrosion trend of the pipeline coating does not increase significantly but rather slows down, indicating that the corrosion process is within a relatively normal range. However, an increasing aging trend of the pipeline coating suggests that the coating material may be undergoing physical or chemical degradation, leading to a weakening of the coating's protective performance. Therefore, the aging problem of the pipeline coating needs attention and is considered a relatively serious situation, warranting a level-two warning.

[0144] When the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, although the corrosion of the first coating is approaching normal, the corrosion degree of the second coating is intensifying, which may indicate that the second coating is facing accelerated corrosion. At the same time, the aging trend is relatively stable, indicating that the aging condition of the pipeline has not deteriorated significantly. This situation suggests that the coating corrosion problem may gradually worsen on the second coating. Therefore, a three-level early warning is needed to take local repair or reinforcement measures.

[0145] When the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, the corrosion trends of both the first and second coatings have intensified, indicating that the protective performance of the pipeline coating has significantly decreased. Even though the aging trend of the pipeline coating remains stable, the corrosion condition is becoming increasingly severe, affecting the structural safety and corrosion resistance of the pipeline. Therefore, this situation represents the most serious warning level, requiring immediate and comprehensive inspection and repair measures, warranting a Level 4 warning.

[0146] It should be noted that by comparing with historical data, abnormal changes in the corrosion trend and aging of the pipeline coating can be detected in a timely manner, ensuring that the system identifies potential problems at an early stage and avoids pipeline failures caused by coating corrosion or aging. This allows for intervention in the early stages of coating corrosion and aging, preventing serious corrosion and aging problems, slowing down the overall deterioration process of the pipeline, thereby significantly extending the service life of the pipeline and reducing pipeline maintenance and replacement costs.

[0147] In some embodiments, determining whether an alarm is needed based on the pipe coating health index and a health index threshold includes:

[0148] An alarm will be triggered if the health index of the pipe coating is lower than the health index threshold.

[0149] If the pipeline health index is greater than or equal to the health index threshold, no alarm will be triggered.

[0150] Specifically, the pipeline coating health index is a quantitative indicator that comprehensively considers multiple factors such as the degree of coating corrosion, aging status, temperature, and humidity. By monitoring and calculating these factors, a comprehensive index reflecting the current health status of the pipeline coating is obtained. A higher health index value indicates stronger protective capabilities and better condition of the pipeline coating; conversely, a lower index indicates a decline in coating performance and potentially more severe corrosion or aging problems.

[0151] It should be noted that this application can quantify the health status of pipe coatings by calculating the health index and comparing thresholds, avoiding reliance on a single factor (such as current value, potential, etc.) and providing a comprehensive and systematic health assessment.

[0152] In some embodiments, the data processing module further includes a visualization unit, which is communicatively connected to the storage unit, the prediction unit, the evaluation unit, and the early warning alarm unit; the visualization unit is configured to display data.

[0153] Specifically, the visualization unit can display real-time values ​​measured by various sensors on the pipeline coating, such as current, potential, temperature, and humidity. This data is presented through charts or dashboards, allowing operators to quickly obtain the current status of the pipeline coating.

[0154] Optionally, by comparing with historical data, the visualization unit can display the health change trend of the pipeline coating over a period of time, helping users understand the degradation process of the coating. Historical data can be displayed in the form of line graphs, trend graphs, or bar charts, facilitating users to perform comparative analysis across time periods. When the system detects an anomaly in the pipeline coating, warning and alarm information will be displayed prominently on the visualization interface.

[0155] For example, different colors (such as red, orange, and yellow) are used to indicate different levels of warning information, ensuring that users can quickly identify and take appropriate measures. The visualization unit helps users assess the current protective performance of the pipeline coating by displaying its health index and its comparison with health index thresholds. This index can be displayed in the form of dashboards, progress bars, or pie charts, intuitively reflecting the overall health status of the pipeline coating.

[0156] As described above, this application provides a pipeline coating integrity monitoring system that employs a passive sensor. This sensor does not rely on an external power source or battery and can harvest energy through electromagnetic fields or radio frequency signals. This reduces reliance on battery replacement and avoids monitoring interruptions caused by battery aging or failure. The passive sensor can operate stably for extended periods without requiring a maintenance power supply, reducing maintenance costs and complexity. The passive sensor is suitable for monitoring tasks in inaccessible and harsh environments such as pipelines.

[0157] Secondly, by real-time monitoring of multi-dimensional data such as current, temperature, potential and humidity of the pipeline coating, combined with the data analysis, prediction and evaluation unit in the data processing module, this application can accurately assess the corrosion rate, aging degree and health index of the pipeline coating, and provide real-time corrosion trend, aging trend and coating integrity status, providing accurate data support for pipeline safety management.

[0158] Furthermore, by comparing and analyzing historical and real-time data, and combining a comprehensive assessment of corrosion rate, aging degree, and health index, this application enables the system to make early warning judgments based on coating corrosion trends, aging trends, and historical data, and to issue alarms based on health index and thresholds. This greatly improves the accuracy and timeliness of early warnings and avoids potential pipeline damage accidents.

[0159] In addition, this application integrates multiple types of sensors, such as electrochemical sensors, temperature sensors, and humidity sensors. By acquiring multidimensional data on the pipeline coating and performing cross-validation, it can more comprehensively and accurately monitor the overall health status of the pipeline and reduce the errors that may be caused by a single sensor.

[0160] Moreover, this application adopts a passive sensor network architecture, which can not only expand the number and coverage of passive sensors according to needs to adapt to various complex pipeline monitoring requirements, but also upgrade the technology and expand the functions.

[0161] Furthermore, the data processing module in this application also includes a visualization unit. This visualization unit can display real-time monitoring data, predicted trends, and health indices through intuitive charts and interfaces, facilitating quick analysis, judgment, and decision-making by operators, thereby improving the efficiency and accuracy of pipeline coating management.

[0162] Furthermore, this application automatically analyzes the health status of pipeline coatings by comparing corrosion and aging trends with historical data, employing advanced weighted algorithms and experience-based models. When the corrosion and aging trends of the pipeline coatings exceed normal ranges, the pipeline coating integrity monitoring system of this application will immediately issue an alarm according to the set early warning rules. The multi-level early warning mechanism can be dynamically adjusted based on the coating's health index and historical data, providing different levels of early warning, such as Level 1 and Level 2, to address varying degrees of risk and ensure pipeline safety. Therefore, the health index-based alarm function of this application can further improve the accuracy and sensitivity of early warnings, ensuring the system responds promptly before danger occurs.

[0163] In some embodiments, such as Figure 3 As shown in the embodiments of this application, a method for monitoring the integrity of pipe coatings is also provided, applied to the above-mentioned... Figure 3 Pipeline coating integrity monitoring includes:

[0164] S301. Obtain the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating.

[0165] S302. Preprocess the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating respectively to obtain the first surface current value, the first surface potential value, the first surface temperature value, and the first ambient humidity value of the pipe coating.

[0166] S303. Determine the corrosion rate and degree of corrosion of the pipeline coating based on the ambient humidity value, surface current value, and surface potential value of the first pipeline coating.

[0167] S304. Determine the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating.

[0168] S305. Determine the corrosion trend of the first coating and the corrosion trend of the second coating based on the corrosion rate and degree of corrosion of the pipeline coating.

[0169] S306. Determine the aging trend of the pipe coating based on the degree of aging of the pipe coating.

[0170] S307. The surface current value, surface potential value, surface temperature value, and ambient humidity value of the first pipeline coating are weighted and summed to determine the pipeline coating health index.

[0171] S308. Based on the corrosion trend of the first coating, the corrosion trend of the second coating, the aging trend of the pipeline coating, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend, determine whether an early warning is needed.

[0172] S309. Determine whether an alarm is needed based on the health index and health index threshold of the pipeline coating.

[0173] In some embodiments, in S302 above, preprocessing is performed on the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating, respectively, including:

[0174] Kalman filtering was used to denoise the surface current, surface potential, surface temperature, and ambient humidity of the pipe coating.

[0175] The surface current value of the first pipe coating satisfies the following formula:

[0176]

[0177] Where I(t) is the surface current value of the pipe coating, and K(t) is the Kalman gain. The predicted surface current value of the pipe coating. The current value on the surface of the first pipe coating.

[0178] The surface potential value of the first pipe coating satisfies the following formula:

[0179]

[0180] Where V(t) is the surface potential value of the pipe coating. The predicted surface potential value of the pipe coating. This is the surface potential value of the first pipe coating.

[0181] The surface temperature of the first pipe coating satisfies the following formula:

[0182]

[0183] Where T(t) is the surface temperature of the pipe coating. The predicted surface temperature of the pipe coating. This is the surface temperature value of the first pipe coating.

[0184] The ambient humidity value of the first pipe coating satisfies the following formula:

[0185]

[0186] Where H(t) is the ambient humidity value of the pipe coating, The predicted ambient humidity value for the pipe coating. The humidity value represents the ambient humidity of the first pipe coating.

[0187] In some embodiments, in S303 above, obtaining the corrosion rate and degree of corrosion of the pipe coating based on the ambient humidity value of the first pipe coating, the surface current value of the first pipe coating, and the surface potential value of the first pipe coating includes:

[0188] The corrosion rate of the first pipe coating is determined based on the surface current value of the first pipe coating; the corrosion rate of the first pipe coating satisfies the following formula:

[0189]

[0190] Where n is the charge transfer number, F is the Faraday constant, A is the area of ​​the electrode, and R... corr (t) represents the corrosion rate of the first pipeline coating.

[0191] The corrosion rate of the first pipeline coating is corrected based on the ambient humidity value to obtain the pipeline coating corrosion rate; the pipeline coating corrosion rate satisfies the following formula:

[0192]

[0193] Where, k H R is the temperature correction factor. corr′(t) represents the corrosion rate of the pipeline coating.

[0194] The degree of corrosion is determined based on the surface potential value of the coating on the first pipe; the degree of corrosion satisfies the following formula:

[0195]

[0196] Among them, C corr (t) represents the degree of corrosion, k1 is the first empirical coefficient, k2 is the second empirical coefficient, and V corr The potential value is given under stable corrosion conditions, where T is temperature and R is the gas constant.

[0197] In some embodiments, S304, determining the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating includes:

[0198] The degree of aging of the pipe coating is determined based on the surface temperature of the first pipe coating; the degree of aging of the pipe coating satisfies the following formula:

[0199]

[0200] Among them, A age (t) represents the aging degree of the pipe coating, A0 is the pre-factor, and E a To activate energy.

[0201] In some embodiments, in S307 above, the surface current value, surface potential value, surface temperature value, and ambient humidity value of the first pipe coating are weighted and summed to determine the pipe coating health index, which satisfies the following formula:

[0202]

[0203] Wherein, CHI is the pipe coating health index, w1 is the first weighting factor, w2 is the second weighting factor, w3 is the third weighting factor, and w4 is the fourth weighting factor.

[0204] In some embodiments, when determining whether an early warning is needed based on the corrosion trend of the first coating, the corrosion trend of the second coating, the aging trend of the pipeline coating, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend in S308, the process includes:

[0205] If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level one warning will be issued.

[0206] If the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is greater than the historical aging trend, then a level two warning will be issued.

[0207] If the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level three warning will be issued.

[0208] If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level four warning will be issued.

[0209] In some embodiments, when determining whether an alarm is needed based on the pipe coating health index and the health index threshold in S309 above, the process includes:

[0210] An alarm will be triggered if the health index of the pipe coating is lower than the health index threshold.

[0211] If the pipeline health index is greater than or equal to the health index threshold, no alarm will be triggered.

[0212] The foregoing mainly describes the solutions provided by the embodiments of this application from a methodological perspective. To achieve the above functions, it includes corresponding hardware structures and / or software modules for executing each function. Those skilled in the art should readily recognize that, based on the units and algorithm steps of the examples described in conjunction with the embodiments disclosed herein, this application can be implemented in hardware or a combination of hardware and computer software. Whether a function is executed in hardware or by computer software driving hardware depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0213] This application embodiment can divide the pipeline coating integrity monitoring device into functional modules according to the above method example. For example, each function can be divided into a separate functional module, or two or more functions can be integrated into one processing module. The integrated module can be implemented in hardware or as a software functional module. Optionally, the module division in this application embodiment is illustrative and only represents one logical functional division; other division methods may be used in actual implementation.

[0214] like Figure 4 The diagram shown is a structural schematic of a pipeline coating integrity monitoring device provided in an embodiment of this application. Figure 4The pipeline coating integrity monitoring device shown includes: a communication unit 401 and a processing unit 402; the communication unit 401 is used to acquire the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipeline coating; the processing unit 402 is used to preprocess the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipeline coating to obtain the first surface current value, first surface potential value, first surface temperature value, and first ambient humidity value of the pipeline coating; the processing unit 402 is also used to determine the corrosion rate and degree of the pipeline coating based on the first ambient humidity value, first surface current value, and first surface potential value of the pipeline coating; the processing unit 402 is also used to determine the corrosion rate and degree of corrosion of the pipeline coating based on the first surface humidity value, first surface current value, and first surface potential value of the pipeline coating; the processing unit 402 is also used to determine the corrosion rate and degree of corrosion of the pipeline coating based on the first surface temperature value of the pipeline coating. The processing unit 402 is used to determine the degree of aging of the pipeline coating based on the corrosion rate and degree of corrosion of the pipeline coating; the processing unit 402 is also used to determine the corrosion trend of the first coating and the corrosion trend of the second coating based on the degree of aging of the pipeline coating; the processing unit 402 is also used to determine the pipeline coating health index by weighted summation of the surface current value, surface potential value, surface temperature value and ambient humidity value of the first pipeline coating; the processing unit 402 is also used to determine whether an early warning is needed based on the corrosion trend of the first coating, the corrosion trend of the second coating, the aging trend of the pipeline coating, the first historical corrosion trend, the second historical corrosion trend and the historical aging trend; the processing unit 402 is also used to determine whether an alarm is needed based on the pipeline coating health index and the health index threshold.

[0215] In some embodiments, the processing unit 402 is specifically used to: apply Kalman filtering to the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating, respectively, for noise reduction. The first surface current value of the pipe coating satisfies the following formula:

[0216]

[0217] Where I(t) is the surface current value of the pipe coating, and K(t) is the Kalman gain. The predicted surface current value of the pipe coating. Let be the surface current value of the first pipe coating. The surface potential value of the first pipe coating satisfies the following formula:

[0218]

[0219] Where V(t) is the surface potential value of the pipe coating. The predicted surface potential value of the pipe coating. Let be the surface potential value of the first pipe coating. The surface temperature value of the first pipe coating satisfies the following formula:

[0220]

[0221] Where T(t) is the surface temperature of the pipe coating. The predicted surface temperature of the pipe coating. The surface temperature of the first pipe coating is given. The ambient humidity of the first pipe coating satisfies the following formula:

[0222]

[0223] Where H(t) is the ambient humidity value of the pipe coating, The predicted ambient humidity value for the pipe coating. The humidity value represents the ambient humidity of the first pipe coating.

[0224] In some embodiments, the processing unit 402 is specifically configured to: determine the corrosion rate of the first pipe coating based on the surface current value of the first pipe coating; the corrosion rate of the first pipe coating satisfies the following formula:

[0225]

[0226] Where n is the charge transfer number, F is the Faraday constant, A is the area of ​​the electrode, and R... corr (t) represents the corrosion rate of the first pipeline coating. The corrosion rate of the first pipeline coating is corrected based on the ambient humidity value to obtain the final pipeline coating corrosion rate; the pipeline coating corrosion rate satisfies the following formula:

[0227]

[0228] Where, k H R is the temperature correction factor. corr′ (t) represents the corrosion rate of the pipe coating. The degree of corrosion is determined based on the surface potential value of the first pipe coating; the degree of corrosion satisfies the following formula:

[0229]

[0230] Among them, C corr (t) represents the degree of corrosion, k1 is the first empirical coefficient, k2 is the second empirical coefficient, and V corr The potential value is given under stable corrosion conditions, where T is temperature and R is the gas constant.

[0231] In some embodiments, the processing unit 402 is specifically configured to: determine the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating; the degree of aging of the pipe coating satisfies the following formula:

[0232]

[0233] Among them, A age (t) represents the aging degree of the pipe coating, A0 is the pre-factor, and E a To activate energy.

[0234] In some embodiments, the surface current value, surface potential value, surface temperature value, and ambient humidity value of the first pipe coating are weighted and summed to determine the pipe coating health index, which satisfies the following formula:

[0235]

[0236] Wherein, CHI is the pipe coating health index, w1 is the first weighting factor, w2 is the second weighting factor, w3 is the third weighting factor, and w4 is the fourth weighting factor.

[0237] In some embodiments, the processing unit 402 is specifically configured to: issue a Level 1 warning if the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend; issue a Level 2 warning if the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is greater than the historical aging trend; issue a Level 3 warning if the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend; and issue a Level 4 warning if the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend.

[0238] In some embodiments, the processing unit 402 is specifically configured to: issue an alarm if the pipeline coating health index is less than the health index threshold; and not issue an alarm if the pipeline health index is greater than or equal to the health index threshold.

[0239] This application also provides a computer program product that can be directly loaded into a memory and contains software code. After being loaded and executed by a computer, the computer program product can implement the pipe coating integrity monitoring method provided in the above embodiments. Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

[0240] The system provided in the above embodiments is only illustrated by the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be further decomposed or combined. For example, the modules in the above embodiments can be merged into one module, or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the various modules or steps and are not considered as an improper limitation of the present invention.

[0241] Those skilled in the art will recognize that the modules and method steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. The programs corresponding to the software modules and method steps can be placed in random access memory (RAM), main memory, read-only memory (ROM), electrically erasable programmable ROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. To clearly illustrate the interchangeability of electronic hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in electronic hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the invention.

Claims

1. A pipeline coating integrity monitoring system, characterized in that, Includes a data acquisition module; The data acquisition module includes: a sensor array unit; The sensor array unit is equipped with passive sensors arranged on the surface of the pipe coating; the passive sensors include: an electrochemical sensor, a temperature sensor, and a humidity sensor; The sensor array unit is configured to acquire the surface current value and surface potential value of the pipe coating through the electrochemical sensor, the surface temperature value of the pipe coating through the temperature sensor, and the ambient humidity value of the pipe coating through the humidity sensor.

2. The pipeline coating integrity monitoring system according to claim 1, characterized in that, The data acquisition module further includes: a transmission unit; The transmission unit is provided with sensor nodes arranged around the electrochemical sensor, the temperature sensor and the humidity sensor; The transmission unit is communicatively connected to the sensor array unit; The transmission unit is configured to transmit the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module via the sensor node.

3. The pipeline coating integrity monitoring system according to claim 2, characterized in that, Also includes: Data processing module; The data processing module includes: a preprocessing unit, a storage unit, a data analysis unit, a prediction unit, an evaluation unit, and an early warning and alarm unit; The preprocessing unit is communicatively connected to the transmission unit; the storage unit is communicatively connected to the preprocessing unit, the data analysis unit, the prediction unit, the evaluation unit, and the early warning alarm unit; the data analysis unit is communicatively connected to the prediction unit; the early warning alarm unit is communicatively connected to both the prediction unit and the evaluation unit. The preprocessing unit is configured to read the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating from the transmission unit, and preprocess the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating respectively to obtain the first surface current value, the first surface potential value, the first surface temperature value, and the first ambient humidity value of the pipe coating. The storage unit is configured to store the surface current value of the first pipe coating, the surface potential value of the first pipe coating, the surface temperature value of the first pipe coating, the ambient humidity value of the first pipe coating, as well as the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend. The data analysis unit is configured to determine the corrosion rate and degree of corrosion of the pipe coating based on the ambient humidity value, the surface current value, and the surface potential value of the first pipe coating; the data analysis unit is also configured to determine the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating. The prediction unit is configured to determine a first coating corrosion trend and a second coating corrosion trend based on the corrosion rate and the degree of corrosion of the pipeline coating; the prediction unit is also configured to determine a pipeline coating aging trend based on the degree of aging of the pipeline coating. The evaluation unit is configured to perform a weighted summation of the surface current value of the first pipe coating, the surface potential value of the first pipe coating, the surface temperature value of the first pipe coating, and the ambient humidity value of the first pipe coating to determine the pipe coating health index. The early warning alarm unit is configured to determine whether an early warning is needed based on the first coating corrosion trend, the second coating corrosion trend, the pipeline coating aging trend, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend; the early warning alarm unit is also configured to determine whether an alarm is needed based on the pipeline coating health index and health index threshold.

4. The pipeline coating integrity monitoring system according to claim 2, characterized in that, The electrochemical sensor, the temperature sensor, and the humidity sensor are all equipped with radio frequency identification (RFID) chips.

5. The pipeline coating integrity monitoring system according to claim 4, characterized in that, The sensor node consists of a passive RFID tag receiver and a wireless communication unit; the transmission of the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module via the sensor node includes: The signals generated by the sensor node trigger the RFID chips in the electrochemical sensor, the temperature sensor, and the humidity sensor, respectively, to transmit the pipe coating surface current value and pipe coating surface potential value measured by the electrochemical sensor to the sensor node, the pipe coating surface temperature value measured by the temperature sensor to the sensor node, and the pipe coating ambient humidity value measured by the humidity sensor to the sensor node. The sensor node transmits the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating to the data processing module.

6. The pipeline coating integrity monitoring system according to claim 3, characterized in that, The process of reading the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating from the transmission unit, and preprocessing the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating respectively, includes: The surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating are read from the transmission unit, and Kalman filtering is applied to the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating for noise reduction. The surface current value of the first pipe coating satisfies the following formula: Where I(t) is the surface current value of the pipe coating, and K(t) is the Kalman gain. The predicted surface current value of the pipe coating. The current value on the surface of the first pipe coating; The surface potential value of the first pipe coating satisfies the following formula: Where V(t) is the surface potential value of the pipe coating. The predicted surface potential value of the pipe coating. The surface potential value of the first pipe coating; The surface temperature of the first pipe coating satisfies the following formula: Where T(t) is the surface temperature of the pipe coating. The predicted surface temperature of the pipe coating. This refers to the surface temperature of the first pipe coating. The ambient humidity value of the first pipe coating satisfies the following formula: Where H(t) is the ambient humidity value of the pipe coating, The predicted ambient humidity value for the pipe coating. The humidity value represents the ambient humidity of the first pipe coating.

7. The pipeline coating integrity monitoring system according to claim 3, characterized in that, When determining the corrosion rate and degree of corrosion of the pipeline coating based on the ambient humidity value, surface current value, and surface potential value of the first pipeline coating, the following steps are included: The corrosion rate of the first pipe coating is determined based on the surface current value of the first pipe coating; the corrosion rate of the first pipe coating satisfies the following formula: Where n is the charge transfer number, F is the Faraday constant, A is the area of ​​the electrode, and R... corr (t) represents the corrosion rate of the first pipeline coating; The corrosion rate of the first pipe coating is corrected based on the ambient humidity value of the first pipe coating to obtain the pipe coating corrosion rate; the pipe coating corrosion rate satisfies the following formula: Where, k H R is the temperature correction factor. corr′ (t) represents the corrosion rate of the pipeline coating; The degree of corrosion is determined based on the surface potential value of the first pipe coating; the degree of corrosion satisfies the following formula: Among them, C corr (t) represents the degree of corrosion, k1 is the first empirical coefficient, k2 is the second empirical coefficient, and V corr The potential value is given under stable corrosion conditions, where T is temperature and R is the gas constant.

8. The pipeline coating integrity monitoring system according to claim 7, characterized in that, When determining the degree of aging of the pipe coating based on the surface temperature value of the first pipe coating, the following steps are included: The degree of aging of the pipe coating is determined based on the surface temperature value of the first pipe coating; the degree of aging of the pipe coating satisfies the following formula: Among them, A age (t) represents the aging degree of the pipe coating, A0 is the pre-factor, and E a To activate energy.

9. The pipeline coating integrity monitoring system according to claim 8, characterized in that, The corrosion tendency of the first coating satisfies the following formula: Among them, T corr1 (t) represents the corrosion trend of the first coating; The corrosion tendency of the second coating satisfies the following formula: Among them, T corr2 (t) represents the corrosion trend of the second coating; The aging trend of the pipeline coating satisfies the following formula: Among them, T age (t) represents the aging trend of the pipeline coating.

10. The pipeline coating integrity monitoring system according to claim 3, characterized in that, The health index of the pipeline coating satisfies the following formula: Wherein, CHI is the pipe coating health index, w1 is the first weighting factor, w2 is the second weighting factor, w3 is the third weighting factor, and w4 is the fourth weighting factor.

11. The pipeline coating integrity monitoring system according to claim 3, characterized in that, When determining whether an early warning is needed based on the first coating corrosion trend, the second coating corrosion trend, the pipeline coating aging trend, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend, the following steps are included: If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a first-level warning is issued. If the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is less than the second historical corrosion trend, and the aging trend of the pipeline coating is greater than the historical aging trend, then a level two warning is issued. If the corrosion trend of the first coating is less than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level three warning is issued. If the corrosion trend of the first coating is greater than the first historical corrosion trend, the corrosion trend of the second coating is greater than the second historical corrosion trend, and the aging trend of the pipeline coating is less than the historical aging trend, then a level four warning is issued.

12. The pipeline coating integrity monitoring system according to claim 3, characterized in that, When determining whether an alarm is needed based on the pipe coating health index and health index threshold, the following steps are included: If the health index of the pipe coating is less than the health index threshold, an alarm will be triggered; If the pipeline health index is greater than or equal to the health index threshold, no alarm will be triggered.

13. The pipeline coating integrity monitoring system according to claim 3, characterized in that, The data processing module further includes a visualization unit, which is communicatively connected to the storage unit, the prediction unit, the evaluation unit, and the early warning alarm unit; the visualization unit is configured to display data.

14. A method for monitoring the integrity of a pipeline coating, characterized in that, The pipeline coating integrity monitoring method, applied to the pipeline coating integrity monitoring system as described in any one of claims 1-13, comprises: Obtain the surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipeline coating; The surface current value, surface potential value, surface temperature value, and ambient humidity value of the pipe coating are preprocessed to obtain the first surface current value, first surface potential value, first surface temperature value, and first ambient humidity value of the pipe coating. The corrosion rate and degree of corrosion of the pipeline coating are determined based on the ambient humidity value of the first pipeline coating, the surface current value of the first pipeline coating, and the surface potential value of the first pipeline coating. The degree of aging of the pipe coating is determined based on the surface temperature value of the first pipe coating. Based on the corrosion rate and the degree of corrosion of the pipeline coating, the corrosion trend of the first coating and the corrosion trend of the second coating are determined. Based on the degree of aging of the pipe coating, determine the aging trend of the pipe coating; The health index of the pipe coating is determined by weighted summation of the surface current value, surface potential value, surface temperature value, and ambient humidity value of the first pipe coating. Based on the first coating corrosion trend, the second coating corrosion trend, the pipeline coating aging trend, the first historical corrosion trend, the second historical corrosion trend, and the historical aging trend, determine whether an early warning is needed; Based on the health index and health index threshold of the pipeline coating, determine whether an alarm is required.

Images