A corrosion monitoring and intelligent early warning device for chemical equipment

Abstract

This utility model relates to the technical field of equipment monitoring devices, and in particular to a corrosion monitoring and intelligent early warning device for chemical equipment. The monitoring housing has two parallel mounting cavities, a first and a second. A sensor assembly is housed in the first mounting cavity. Both the first and second mounting cavities have open front sides that connect to the interior of a support frame. Both sensor assemblies extend through the open structures into the support frame. The rear sides of both the first and second mounting cavities connect to a third mounting cavity, which houses a controller and a power module. Sensor assemblies 1 and 2 are electrically connected to the controller and the power module, respectively. This utility model, employing the aforementioned corrosion monitoring and intelligent early warning device for chemical equipment, achieves multi-dimensional real-time monitoring and intelligent early warning of the corrosion status of chemical equipment pipelines, ensuring the safe and stable operation of chemical production.

Description

Technical Field

[0001] This utility model relates to the field of equipment monitoring device technology, and in particular to a corrosion monitoring and intelligent early warning device for chemical equipment. Background Technology

[0002] In chemical production processes, pipelines, as key components for material transportation, are subjected to complex and highly corrosive environments such as high temperature, high pressure, and strong acids and alkalis for extended periods. Pipeline corrosion leads to thinning of the pipe walls and a decrease in strength, which in turn causes serious problems such as material leakage and pressure imbalance. This not only causes huge economic losses but may also trigger major safety accidents such as fires and explosions, posing a serious threat to human life and the environment.

[0003] Currently, existing methods for monitoring corrosion in chemical equipment pipelines have many shortcomings. Some monitoring devices employ single methods, such as relying solely on periodic manual inspections of the pipeline's exterior or using simple wall thickness measuring tools. These methods cannot achieve real-time, comprehensive monitoring and are insufficient for timely detection of internal corrosion. Some sensor-based monitoring devices suffer from unreasonable sensor layouts, inconvenient installation and maintenance, and a lack of effective data processing and early warning mechanisms. They cannot accurately assess the degree of pipeline corrosion and remaining lifespan, failing to meet the stringent requirements for safe pipeline operation in chemical production. Therefore, there is an urgent need for a corrosion monitoring device for chemical equipment pipelines that can achieve multi-dimensional, real-time, and accurate monitoring with intelligent early warning capabilities. Utility Model Content

[0004] The purpose of this invention is to provide a corrosion monitoring and intelligent early warning device for chemical equipment, enabling multi-dimensional real-time monitoring and intelligent early warning of the corrosion status of chemical equipment pipelines, thereby ensuring the safe and stable operation of chemical production.

[0005] To achieve the above objectives, this utility model provides a corrosion monitoring and intelligent early warning device for chemical equipment, including a support frame and a monitoring box. A clamping mechanism is provided on one side of the support frame, and the monitoring box is fixedly connected to the other side of the support frame. The monitoring box contains two parallel mounting cavities, a first mounting cavity and a second mounting cavity. The first mounting cavity contains a sensor assembly, which includes a linear polarization resistance sensor and an electrochemical impedance spectroscopy sensor. The second mounting cavity contains a sensor assembly, which includes a pulse-echo ultrasonic sensor and a distributed fiber optic sensor. Both the first and second mounting cavities have open front sides that communicate with the interior of the support frame. Both sensor assemblies extend through the open structures into the support frame. The rear sides of both the first and second mounting cavities communicate with a third mounting cavity, which contains a controller and a power module. The first and second sensor assemblies are electrically connected to the controller and the power module, respectively.

[0006] Preferably, heat dissipation holes are provided on both the top and bottom sides of the monitoring box.

[0007] Preferably, two sets of clamping mechanisms are arranged parallel to each other vertically, and the two sets of clamping mechanisms are symmetrically arranged on the upper and lower sides of the open structure. The clamping mechanism includes an electric slide rail and an arc-shaped clamping plate. The electric slide rail is electrically connected to the controller and the power module respectively, and the arc-shaped clamping plate is fixedly connected to the slide rail of the electric slide rail.

[0008] Preferably, the inner arc surface of the arc-shaped clamping plate is provided with several evenly distributed arc-shaped protrusions, which are made of rubber.

[0009] Preferably, a protective plate is fixedly connected to the upper side of the opening structure of the first mounting cavity, and the end face of the protective plate is flush with the end face of the sensor assembly. A protective plate is fixedly connected to the upper side of the opening structure of the second mounting cavity, and the end face of the protective plate is flush with the end face of the sensor assembly.

[0010] Preferably, a cover is provided on one side of the mounting cavity 1 and mounting cavity 2, and a magnetic strip 1 is provided at the end of the cover near the support frame, and a magnetic strip 2 matching the magnetic strip 1 is provided on the support frame.

[0011] Preferably, the controller is equipped with a data acquisition module, a data processing and analysis module, and an early warning module. The data acquisition module includes an ARM series chip and an A / D conversion chip. The data processing and analysis module includes an embedded processor with corrosion monitoring data analysis software installed on it. The early warning module includes an audible and visual alarm mechanism and a wireless communication module, which is connected to the remote control device.

[0012] Therefore, this utility model provides a corrosion monitoring and intelligent early warning device for chemical equipment using the above-mentioned structure. By combining multiple sensors such as linear polarization resistance and electrochemical impedance spectroscopy, it achieves real-time monitoring of electrochemical corrosion and wall thickness changes in chemical equipment pipelines from multiple dimensions, significantly improving accuracy and reliability compared to single methods. Utilizing a controller-mounted module and corrosion prediction model, it provides intelligent early warning through sound, light, and wireless communication when thresholds are exceeded, ensuring production safety. The clamping mechanism and magnetic cover are adaptable to pipelines of different diameters, facilitating installation and maintenance while protecting the pipeline surface. The monitoring box has a reasonable layout, and its heat dissipation and protection design promotes stable operation of the device and extends sensor lifespan.

[0013] The technical solution of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of a corrosion monitoring and intelligent early warning device for chemical equipment according to this utility model;

[0015] Figure 2This is a schematic diagram of the present invention without sensor assembly one and sensor assembly two installed;

[0016] Figure 3 This is a side view of a corrosion monitoring and intelligent early warning device for chemical equipment according to this utility model;

[0017] Figure 4 This is a utility model Figure 3 A magnified view of a portion of point A in the middle.

[0018] Figure label:

[0019] 1. Support frame; 2. Monitoring box body; 21. Mounting cavity one; 22. Mounting cavity two; 23. Protective plate one; 24. Protective plate two; 3. Heat dissipation holes; 4. Clamping mechanism; 41. Electric slide rail; 42. Arc-shaped clamping plate; 43. Arc-shaped protrusion; 5. Sensor assembly one; 6. Sensor assembly two; 7. Cover; 8. Magnetic strip one; 9. Magnetic strip two; 10. Audible and visual alarm mechanism. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments. Unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The features mentioned above or in the specific examples mentioned in this invention can be combined arbitrarily, and these specific embodiments are only used to illustrate this invention and are not intended to limit the scope of this invention.

[0021] Example

[0022] like Figures 1 to 4 As shown, this utility model provides a corrosion monitoring and intelligent early warning device for chemical equipment, including a support frame 1 and a monitoring box 2. The monitoring box 2 has heat dissipation holes 3 on both its upper and lower sides, which effectively promotes heat dissipation within the monitoring box 2 and prevents heat accumulation caused by the operation of internal components from affecting the device's performance. A clamping mechanism 4 is provided on one side of the support frame 1 for securely installing the device on the chemical equipment pipeline.

[0023] The monitoring box 2 is fixedly connected to the other side of the support frame 1. The monitoring box 2 has two parallel mounting cavities, namely, a first mounting cavity 21 and a second mounting cavity 22. The first mounting cavity 21 contains a sensor assembly 5, and the second mounting cavity 22 contains a sensor assembly 6. The front of both the first mounting cavity 21 and the second mounting cavity 22 are open structures, which are connected to the interior of the support frame 1. The first sensor assembly 5 and the second sensor assembly 6 extend through the open structures into the support frame 1, which facilitates close contact with the surface of the chemical equipment pipeline after installation, so as to achieve effective monitoring.

[0024] A protective plate 23 is fixedly connected to the upper side of the opening structure of mounting cavity 21. The end face of the protective plate 23 is flush with the end face of sensor assembly 5. A protective plate 24 is fixedly connected to the upper side of the opening structure of mounting cavity 22. The end face of the protective plate 24 is flush with the end face of sensor assembly 6. After installation, the protective plates 23 and 24 abut against the surface of the chemical equipment pipeline, respectively, protecting sensor assembly 5 and sensor assembly 6 and preventing them from being damaged by collision or compression with the chemical equipment pipeline.

[0025] A cover 7 is also provided on one side of the mounting cavity 1 21 and the mounting cavity 22. A magnetic strip 8 is provided at the end of the cover 7 near the support frame 1, and a magnetic strip 9 matching the magnetic strip 8 is provided on the support frame 1. The cooperation of the magnetic strip 8 and the magnetic strip 9 facilitates the installation and removal of the cover 7. When not in use, the cover 7 can be installed for protection, and when in use, the cover 7 can be removed, which is simple and convenient.

[0026] Sensor component 1 (5) includes a linear polarization resistance sensor and an electrochemical impedance spectroscopy (EIS) sensor. The linear polarization resistance sensor can quickly acquire the instantaneous corrosion rate of the metal pipeline. The EIS sensor, by measuring the impedance spectrum of the electrode system, provides in-depth analysis of the kinetics and corrosion mechanisms of the pipeline corrosion process. Sensor component 2 (6) includes a pulse-echo ultrasonic sensor and a distributed fiber optic sensor. The pulse-echo ultrasonic sensor periodically emits ultrasonic pulses towards the pipeline wall; by measuring the time interval of the reflected echoes, it accurately calculates the remaining thickness of the pipeline wall, thereby determining the degree of corrosion. The distributed fiber optic sensor reflects the corrosion state of the pipeline by monitoring the temperature and strain changes on the pipeline surface in real time.

[0027] The rear sides of both mounting chamber 1 (21) and mounting chamber 2 (22) are connected to mounting chamber 3. Mounting chamber 3 houses a controller and a power module (the structure of the controller and power module is prior art and not shown in the accompanying drawings). Sensor assembly 1 (5) and sensor assembly 2 (6) are electrically connected to the controller and power module, respectively. The controller is equipped with a data acquisition module, a data processing and analysis module, and an early warning module. The data acquisition module includes an ARM series chip and an A / D conversion chip, capable of quickly and accurately acquiring the analog signals output by sensor assembly 1 (5) and sensor assembly 2 (6) and converting them into digital signals. The data processing and analysis module includes an embedded processor with corrosion monitoring data analysis software installed. This software can preprocess the acquired data, extract features, and use machine learning algorithms to establish a corrosion prediction model, calculating parameters such as the corrosion rate and remaining life of the pipeline in real time. The early warning module includes an audible and visual alarm mechanism 10 and a wireless communication module. The wireless communication module is connected to the remote control device. When the corrosion parameters calculated by the data processing and analysis module exceed the preset safety threshold, the audible and visual alarm mechanism 10 immediately emits a strong audible and visual signal to alert on-site personnel. At the same time, the wireless communication module sends the early warning information to the remote control device through the wireless network so that management personnel can understand the abnormal situation of the pipeline in a timely manner and take corresponding measures.

[0028] Two sets of clamping mechanisms 4 are arranged parallel to each other vertically, symmetrically positioned on the upper and lower sides of the open structure. Each clamping mechanism 4 includes an electric slide rail 41 and an arc-shaped clamping plate 42. The electric slide rail 41 is electrically connected to both the controller and the power module. The arc-shaped clamping plate 42 is fixedly connected to the slide rail of the electric slide rail 41. By controlling the operation of the electric slide rail 41 through the controller, the position of the arc-shaped clamping plate 42 can be adjusted, thereby achieving stable clamping of chemical equipment pipelines of different diameters. The inner arc surface of the arc-shaped clamping plate 42 is provided with several evenly distributed arc-shaped protrusions 43. The arc-shaped protrusions 43 are made of rubber, which increases the friction with the pipeline surface, further improving the stability of the clamping while avoiding damage to the pipeline surface.

[0029] Specific work process:

[0030] Align the side of the support frame 1 with the clamping mechanism 4 with the chemical equipment pipeline. Activate the electric slide rail 41 via the controller. The slider of the electric slide rail 41 drives the arc-shaped clamping plates 42 on both sides to simultaneously approach the chemical equipment pipeline until the rubber arc-shaped protrusions 43 are tightly against the surface of the chemical equipment pipeline. At this point, sensor assembly 5 and sensor assembly 6 are both in contact with the surface of the chemical equipment pipeline, converting the collected information into analog electrical signals. The data acquisition module collects the analog electrical signals output by sensor assembly 5 and sensor assembly 6, converts them into digital signals, and transmits them to the data processing and analysis module to comprehensively assess the corrosion status of the pipeline. When the corrosion parameters calculated by the data processing and analysis module exceed the preset safety threshold, the early warning module is immediately triggered. The audible and visual alarm mechanism 10 emits a strong audible and visual signal to alert on-site personnel to potential abnormal corrosion in the pipeline. Simultaneously, the wireless communication module sends the early warning information to a remote control device (such as a manager's mobile phone, tablet, or the server in the monitoring center) via a wireless network. Upon receiving the early warning information, the manager can promptly arrange for professional personnel to further inspect and repair the pipeline to prevent accidents.

[0031] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although the utility model 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 solution of this utility model, and these modifications or equivalent substitutions cannot cause the modified technical solution to deviate from the spirit and scope of the technical solution of this utility model.

Claims

1. A corrosion monitoring and intelligent early warning device for chemical equipment, characterized in that: The device includes a support frame and a monitoring box. A clamping mechanism is located on one side of the support frame, and the monitoring box is fixedly connected to the other side of the support frame. The monitoring box contains two parallel mounting cavities: a first mounting cavity and a second mounting cavity. The first mounting cavity houses a sensor assembly, which includes a linear polarization resistance sensor and an electrochemical impedance spectroscopy sensor. The second mounting cavity houses a sensor assembly, which includes a pulse-echo ultrasonic sensor and a distributed fiber optic sensor. Both the first and second mounting cavities have open front sides that communicate with the interior of the support frame. Both sensor assemblies extend through the open structures into the support frame. The rear sides of both the first and second mounting cavities communicate with a third mounting cavity, which houses a controller and a power module. The first and second sensor assemblies are electrically connected to the controller and the power module, respectively.

2. The corrosion monitoring and intelligent early warning device for chemical equipment according to claim 1, characterized in that: The monitoring box has ventilation holes on both the top and bottom sides.

3. The corrosion monitoring and intelligent early warning device for chemical equipment according to claim 1, characterized in that: Two sets of clamping mechanisms are arranged parallel to each other vertically. The two sets of clamping mechanisms are symmetrically arranged on the upper and lower sides of the open structure. The clamping mechanism includes an electric slide rail and an arc-shaped clamping plate. The electric slide rail is electrically connected to the controller and the power module respectively. The arc-shaped clamping plate is fixedly connected to the slide rail of the electric slide rail.

4. The corrosion monitoring and intelligent early warning device for chemical equipment according to claim 3, characterized in that: The inner arc surface of the arc-shaped clamping plate has several evenly distributed arc-shaped protrusions, which are made of rubber.

5. The corrosion monitoring and intelligent early warning device for chemical equipment according to claim 1, characterized in that: A protective plate is fixedly connected to the upper side of the opening structure of the first mounting cavity. The end face of the protective plate is flush with the end face of the sensor assembly. A protective plate is fixedly connected to the upper side of the opening structure of the second mounting cavity. The end face of the protective plate is flush with the end face of the sensor assembly.

6. The corrosion monitoring and intelligent early warning device for chemical equipment according to claim 1, characterized in that: A cover is provided on one side of the mounting cavity 1 and mounting cavity 2, and a magnetic strip 1 is provided at the end of the cover near the support frame. A magnetic strip 2 that matches the magnetic strip 1 is provided on the support frame.

7. The device according to claim 1, characterized in that: The controller is equipped with a data acquisition module, a data processing and analysis module, and an early warning module. The data acquisition module includes an ARM series chip and an A / D conversion chip. The data processing and analysis module includes an embedded processor with corrosion monitoring data analysis software installed on it. The early warning module includes an audible and visual alarm mechanism and a wireless communication module, which is connected to the remote control device.

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