An oil and gas pipeline sensor probe device based on weak magnetic detection

Abstract

The utility model discloses an oil gas pipeline sensor probe device based on weak magnetic detection, including probe main part, magnetization unit, magnetosensitive sensor array, signal processing module and protection shell, probe main part is cylindrical, is equipped with the connection interface in one end, magnetization unit installs in the inside of probe main part, adopts permanent magnet and forms ring arrangement, and carries out magnetization to oil gas pipeline, magnetosensitive sensor array is composed of multiple magnetosensitive sensors, evenly distributes on the surface of probe main part, forms annular detection surface, and adjacent two magnetosensitive sensors form differential pair, signal processing module is installed on probe main part, and is connected with magnetosensitive sensor array, and includes preamplifier, filter, adc and microprocessor, and protection shell is wrapped in the outside of probe main part. Can all -round cover pipeline circumference, realizes the detection to pipeline circumferential arbitrary position defect, has improved the overall performance and accuracy of detection greatly, provides reliable guarantee for the safe operation of oil gas pipeline.

Description

Technical Field

[0001] This utility model belongs to the field of oil and gas pipeline detection technology, and relates to an oil and gas pipeline sensor probe device based on weak magnetic field detection. Background Technology

[0002] Oil and gas pipelines, as critical infrastructure for energy transportation, occupy a pivotal position in national economic and social development. They bear the heavy responsibility of efficiently and stably transporting vital energy sources such as oil and natural gas from production sites to consumption sites, serving as a crucial support for ensuring national energy security and promoting sustained and healthy economic development. Once a safety accident occurs in an oil and gas pipeline, it will not only lead to energy supply disruptions and affect normal production and daily life, but may also trigger serious disasters such as fires and explosions, posing a significant threat to people's lives and property. Simultaneously, oil and gas leaks will cause severe pollution to environmental elements such as soil, water bodies, and the atmosphere, disrupting the ecological balance and causing long-term and irreversible damage to the ecological environment. Therefore, ensuring the safe operation of oil and gas pipelines is of paramount practical importance.

[0003] During long-term operation, oil and gas pipelines are inevitably affected by various factors, leading to various defects. Soil corrosion is one of the main threats to oil and gas pipelines. Since most oil and gas pipelines are buried underground and in direct contact with the soil, moisture, oxygen, salt, and microorganisms in the soil will undergo complex electrochemical corrosion reactions with the pipeline metal, gradually eroding the pipeline surface and reducing the pipeline's wall thickness and strength. Over time, the degree of corrosion continues to intensify, eventually potentially leading to pipeline perforation and leakage.

[0004] To promptly detect and address defects in oil and gas pipelines and ensure their safe operation, various detection methods have been developed, including ultrasonic testing and radiographic testing. However, these methods all have certain limitations in practical applications.

[0005] Ultrasonic testing utilizes the properties of ultrasound waves to detect defects in materials, such as reflection, refraction, and scattering when they encounter them. It detects defects by receiving and analyzing the reflected waves. It offers advantages such as large detection depth, high sensitivity, and harmlessness to humans, and can detect internal defects like cracks and pores in pipes. However, ultrasonic testing requires a high degree of surface smoothness in the pipes; pre-cleaning and polishing of the pipe surface are necessary to ensure accurate test results.

[0006] Radiographic inspection utilizes the difference in absorption and scattering of radiation at defective locations compared to normal areas when radiation penetrates pipe materials. This difference is used to create images of varying densities on film, thus detecting defects. Radiographic inspection can visually display the shape, size, and location of defects, and the results are highly reliable and traceable. However, radiographic inspection poses radiation hazards, requiring strict protective measures to ensure the safety of operators and the surrounding environment.

[0007] In summary, while existing oil and gas pipeline inspection methods can detect pipeline defects to some extent, they all suffer from drawbacks such as low inspection efficiency, high cost, and high requirements for pipeline surface, making it difficult to meet the needs of large-scale, rapid, and accurate inspection of oil and gas pipelines. Summary of the Invention

[0008] The purpose of this invention is to solve the problems of low detection efficiency, high cost, and high requirements for pipeline surface in the existing oil and gas pipeline detection technology, and to provide an oil and gas pipeline sensor probe device based on weak magnetic field detection.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: A sensor probe device for oil and gas pipelines based on weak magnetic field detection includes a probe body, a magnetization unit, a magnetic sensor array, a signal processing module, and a protective housing; The probe body is cylindrical, with a connection interface at one end; The magnetization unit is installed inside the probe body and uses permanent magnets arranged in a ring to magnetize the oil and gas pipeline. The magnetic sensor array consists of multiple magnetic sensors, which are evenly distributed on the surface of the probe body to form a ring detection surface. Two adjacent magnetic sensors form a differential pair. The signal processing module is mounted on the probe body and connected to the magnetic sensor array, including a preamplifier, filter, analog-to-digital converter and microprocessor; The protective shell is wrapped around the outside of the probe body.

[0010] One end of the probe body is provided with a standardized connection interface for connecting and communicating with external detection equipment. The connection interface is circular or square in shape and adopts threaded connection, snap-fit ​​connection or plug-in connection. The interface is provided with electrical contact points for realizing electrical signal transmission between the internal signal processing module of the probe and the external data acquisition system, as well as a mechanical positioning structure for ensuring the accurate position and orientation of the probe when connected. The mechanical positioning structure adopts the method of positioning pin and positioning hole cooperation.

[0011] The probe body has multiple cavities inside, including a magnetization unit mounting cavity located at the front end or middle for mounting the magnetization unit, and a fixing device inside for fixing the magnetization unit by means of bolt fastening, slot fixing or elastic clamping. It also includes a magnetic sensor array mounting cavity distributed on the outer peripheral surface of the probe body, which is in the shape of a ring or arc. The cavity has multiple sensor mounting positions that match the size and shape of the magnetic sensor used, and an insulating isolation layer is provided between the sensor mounting positions. And a rectangular signal processing module mounting cavity located at the rear of the probe body, with a heat dissipation structure inside the cavity.

[0012] The insulating layer inside the mounting cavity of the magnetic sensor array is made of alumina ceramic with a thickness between 0.05 and 0.2 mm.

[0013] The magnetization unit is installed inside the probe body and mainly consists of a permanent magnet, a magnetic yoke, a fixing bracket, and an adjustment mechanism. The permanent magnets are high-performance neodymium iron boron permanent magnets, and each permanent magnet is processed into a cuboid or trapezoidal shape to meet the requirements of ring arrangement; The magnetic yoke is made of stacked cold-rolled silicon steel sheets in a circular shape. Its inner diameter is larger than the internal space diameter of the probe body used to install other components, and its outer diameter is determined according to the arrangement of permanent magnets and the required magnetic field coverage. The thickness of the silicon steel sheets is between 0.3 and 0.5 mm. The fixing bracket is used to firmly fix the permanent magnet to the magnetic yoke. It is made of non-magnetic material and has a slot on the bracket that matches the shape of the permanent magnet. The permanent magnet is embedded in the slot and fixed by bolts or buckles. The adjustment mechanism adjusts the strength and distribution of the magnetic field according to different oil and gas pipeline materials, sizes, and testing requirements; the adjustment mechanism adjusts the magnetic field strength by rotating the screw to change the relative position between the permanent magnet and the yoke.

[0014] Multiple permanent magnets are evenly distributed on the circumference of the yoke, and the spacing between adjacent permanent magnets remains consistent.

[0015] The adjustment mechanism also includes a dial and a pointer. The dial is fixed on the magnetic yoke, and the pointer is mounted on the rotating screw. When the rotating screw adjusts the relative position between the permanent magnet and the magnetic yoke, the pointer indicates the corresponding position on the dial.

[0016] The magnetic sensor is either a Hall sensor or a magnetoresistive sensor.

[0017] The probe body is also equipped with a status indicator light, which is connected to the microprocessor in the signal processing module to display the working status of the probe device.

[0018] The protective shell is provided with multiple heat dissipation holes, which are evenly distributed in a circular shape and have a diameter between 1 and 3 mm.

[0019] Compared with the prior art, the present invention has the following beneficial effects: This invention discloses a sensor probe device for oil and gas pipelines based on weak magnetic field detection. The magnetization unit comprises permanent magnets arranged in a ring inside the probe body, providing a uniform and stable magnetic field to fully magnetize the pipeline. A magnetic sensor array is uniformly distributed on the probe body surface to form a ring-shaped detection surface, capable of omnidirectionally covering the pipeline circumference and detecting defects at any location along the pipeline's circumference. This significantly improves the comprehensiveness and accuracy of the detection, providing a reliable guarantee for the safe operation of oil and gas pipelines.

[0020] Two adjacent magnetic sensors form a differential pair. When a defect in the pipeline causes a local change in the magnetic field, the differential pair can effectively extract the weak signal related to the defect while suppressing common-mode interference signals. This significantly improves the signal-to-noise ratio, making the defect signal clearer and more prominent, further enhancing the accuracy and reliability of detection, and enabling more precise identification of the type, location, and severity of pipeline defects.

[0021] The signal processing module is integrated into the probe body and tightly connected to the magnetic sensor array. It includes a preamplifier, filter, analog-to-digital converter, and microprocessor. The preamplifier initially amplifies the weak signal output from the magnetic sensor, increasing the signal amplitude; the filter removes noise and interference components from the signal, making it cleaner; the analog-to-digital converter converts the analog signal into a digital signal, facilitating subsequent processing by the microprocessor. This allows for rapid and efficient processing of the detection signal, ensuring data accuracy and timeliness. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a structural block diagram of the oil and gas pipeline sensor probe device based on weak magnetic field detection according to this utility model. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0025] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0026] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0027] The present invention will now be described in further detail with reference to the accompanying drawings: See Figure 1 The diagram shows the structural block of the oil and gas pipeline sensor probe device based on weak magnetic field detection according to this utility model. The oil and gas pipeline sensor probe device based on weak magnetic field detection according to this utility model includes a probe body, a magnetization unit, a magnetic sensor array, a signal processing module, and a protective shell. The probe body is cylindrical with a connection interface at one end. This interface, which is circular or square in shape and uses threaded, snap-fit, or plug-in connections, provides electrical contact points for signal transmission between the probe's internal signal processing module and the external data acquisition system. It also includes a mechanical positioning structure to ensure accurate positioning and orientation during probe connection, employing a positioning pin and positioning hole combination. The probe body contains multiple cavities, including a magnetization unit mounting cavity at the front or middle for mounting the magnetization unit, with a fixing device using bolts, slots, or elastic clamps. It also includes ring-shaped or arc-shaped magnetic sensor array mounting cavities distributed on the outer surface of the probe body, each with multiple sensor mounting positions matching the size and shape of the magnetic sensors used, separated by an insulating layer. Finally, it includes a rectangular signal processing module mounting cavity at the rear of the probe body, with a heat dissipation structure inside. The insulating layer inside the mounting cavity of the magnetic sensor array is made of alumina ceramic with a thickness between 0.05 and 0.2 mm.

[0028] The magnetization unit is installed inside the probe body and uses permanent magnets arranged in a ring to magnetize the oil and gas pipeline. The magnetization unit is installed as a whole in the internal space of the probe body and mainly consists of permanent magnets, a magnetic yoke, a fixing bracket, and an adjustment mechanism. The permanent magnets are high-performance neodymium iron boron permanent magnets, each of which is processed into a cuboid or trapezoidal shape to meet the requirements of the ring arrangement. The magnetic yoke is made of cold-rolled silicon steel sheets stacked together, in a ring shape, with an inner diameter larger than the diameter of the space inside the probe body used to install other components, and the outer diameter determined according to the arrangement of the permanent magnets and the required magnetic field coverage. The thickness of the silicon steel sheets is between 0.3 and 0.5 mm. The fixing bracket is used to firmly fix the permanent magnets to the magnetic yoke. It is made of non-magnetic material and has a slot on the bracket that matches the shape of the permanent magnet. The permanent magnet is embedded in the slot and fixed by bolts or buckles. The adjustment mechanism adjusts the strength and distribution of the magnetic field according to different oil and gas pipeline materials, sizes, and detection requirements. The adjustment mechanism adjusts the magnetic field strength by rotating a screw to change the relative position between the permanent magnet and the magnetic yoke. Multiple permanent magnets are evenly distributed on the circumference of the yoke, with the spacing between adjacent permanent magnets remaining consistent. The adjustment mechanism also includes a dial and a pointer. The dial is fixed to the yoke, and the pointer is mounted on a rotating screw. When the rotating screw adjusts the relative position between the permanent magnets and the yoke, the pointer indicates the corresponding position on the dial.

[0029] The magnetic sensor array consists of multiple magnetic sensors, which are evenly distributed on the surface of the probe body to form a ring detection surface. Two adjacent magnetic sensors form a differential pair. The magnetic sensors are Hall sensors or magnetoresistive sensors.

[0030] The signal processing module is mounted on the probe body and connected to the magnetic sensor array, including a preamplifier, filter, analog-to-digital converter and microprocessor; The protective shell covers the outside of the probe body. The protective shell has multiple heat dissipation holes, which are evenly distributed in a circular pattern and have a diameter between 1 and 3 mm.

[0031] The probe body is also equipped with a status indicator light, which is connected to the microprocessor in the signal processing module to display the working status of the probe device. Example

[0032] The probe body features a cylindrical design and is made of high-strength aluminum alloy, offering advantages such as light weight, high strength, and corrosion resistance, making it suitable for the complex inspection environment of oil and gas pipelines. The probe body has a diameter of 80mm and a length of 200mm, with a standardized connection interface at one end. The connection interface is circular and uses a threaded connection. Internally, the interface has eight electrical contact points for transmitting electrical signals between the probe's internal signal processing module and the external data acquisition system. A mechanical positioning structure is also included at the interface, employing a 5mm diameter positioning pin and an 8mm deep positioning hole to ensure accurate positioning and orientation of the probe during connection and prevent misalignment.

[0033] The magnetization unit is installed inside the probe body and uses high-performance neodymium iron boron permanent magnets arranged in a ring. A total of 12 permanent magnets are used, each of which is machined into a cuboid shape with dimensions of 20mm × 10mm × 5mm to meet the requirements of the ring arrangement. The permanent magnets are evenly distributed on the circumference of the yoke, and the spacing between adjacent permanent magnets is consistent at 5mm.

[0034] The magnetic yoke is made of stacked cold-rolled silicon steel sheets in a circular ring shape. Its inner diameter is 60mm, larger than the internal diameter of the probe body used to install other components. The outer diameter is 100mm, determined based on the arrangement of the permanent magnets and the required magnetic field coverage. The silicon steel sheets are 0.4mm thick, effectively reducing eddy current losses and improving magnetization efficiency.

[0035] The mounting bracket, made of non-magnetic polytetrafluoroethylene (PTFE), is used to securely fix the permanent magnet to the yoke. The bracket has a slot that matches the shape of the permanent magnet, with a depth of 4mm. The permanent magnet is embedded in the slot and secured with bolts to ensure that it does not shift during testing.

[0036] The adjustment mechanism adjusts the strength and distribution of the magnetic field according to different oil and gas pipeline materials, sizes, and testing requirements. The adjustment mechanism changes the relative position between the permanent magnet and the yoke by rotating a screw to adjust the magnetic field strength. The screw pitch is 1mm; with each rotation, the permanent magnet moves 1mm relative to the yoke, thus achieving precise adjustment of the magnetic field strength.

[0037] The magnetic sensor array consists of 24 Hall effect magnetic sensors, evenly distributed on the surface of the probe body to form a ring-shaped detection surface. Adjacent magnetic sensors form differential pairs, totaling 12 pairs. Each magnetic sensor surface is coated with a 0.2mm thick polytetrafluoroethylene (PTFE) anti-corrosion coating to protect it from corrosion in the complex environment of oil and gas pipelines.

[0038] The magnetic sensor mounting cavities are distributed on the outer peripheral surface of the probe body and are ring-shaped. Inside the cavity, there are 24 sensor mounting positions that match the size and shape of the magnetic sensors. An alumina ceramic insulating layer with a thickness of 0.1 mm is placed between the sensor mounting positions. This insulating layer has good insulation and high temperature resistance, and can effectively prevent electrical interference between adjacent magnetic sensors.

[0039] The signal processing module is installed in a rectangular mounting cavity at the rear of the probe body, containing a heat dissipation structure. This structure consists of a heat sink and a cooling fan. The heat sink is made of copper and has multiple fins on its surface. The 5W cooling fan uses forced convection to accelerate airflow, carrying away heat from the heat sink and ensuring the signal processing module operates within its normal operating temperature range.

[0040] The signal processing module includes a preamplifier, filter, analog-to-digital converter (ADC), and microprocessor. The preamplifier is a low-noise, high-input-impedance instrumentation amplifier with an adjustable gain range of 10-1000 times, capable of initially amplifying the weak signal output from the magnetic sensor. The filter is a bandpass filter with a passband frequency range of 1Hz-10kHz, set according to the characteristics of the weak magnetic signal in oil and gas pipelines, effectively removing noise and interference components from the signal. The ADC has a 12-bit sampling accuracy and a sampling frequency of 120kHz, meeting the requirements for accurate acquisition of weak magnetic signals. The microprocessor uses an ARM architecture processor to perform real-time analysis and processing of the digital signal output from the ADC, realizing functions such as signal feature extraction and defect identification, and transmitting the detection data to an external data acquisition system via a connection interface.

[0041] The protective shell, encasing the probe body, is made of an alloy of polycarbonate and acrylonitrile-butadiene-styrene copolymer, characterized by high strength, wear resistance, and a degree of flexibility. The surface of the protective shell is frosted to increase friction and facilitate gripping. Multiple circular, evenly distributed ventilation holes, each 2mm in diameter, are present on the protective shell to promote heat dissipation from the probe's interior.

[0042] Work process In actual testing, the sensor probe is connected to an external data acquisition system via a connection interface. The probe is placed on the surface of the oil and gas pipeline, and the ring-shaped magnetic field generated by the magnetization unit magnetizes the pipeline. When a defect exists in the pipeline, it causes a change in the local magnetic field. The differential pairs in the magnetic sensor array can detect this weak magnetic field change and convert it into an electrical signal. The electrical signal is transmitted to the signal processing module, amplified by a preamplifier, filtered by a filter, and converted by an analog-to-digital converter. The microprocessor then analyzes and processes the signal to identify the type, location, and severity of the pipeline defect. The detected data is then transmitted to the external data acquisition system for storage and display, thus achieving effective detection of the oil and gas pipeline.

[0043] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An oil and gas pipeline sensor probe apparatus based on weak magnetic field detection, characterized by, It includes the probe body, magnetization unit, magnetic sensor array, signal processing module, and protective housing; The probe body is cylindrical, with a connection interface at one end; The magnetization unit is installed inside the probe body and uses permanent magnets arranged in a ring to magnetize the oil and gas pipeline. The magnetic sensor array consists of multiple magnetic sensors, which are evenly distributed on the surface of the probe body to form a ring detection surface. Two adjacent magnetic sensors form a differential pair. The signal processing module is mounted on the probe body and connected to the magnetic sensor array, including a preamplifier, filter, analog-to-digital converter and microprocessor; The protective shell is wrapped around the outside of the probe body.

2. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 1, characterized in that, One end of the probe body is provided with a standardized connection interface for connecting and communicating with external detection equipment. The connection interface is circular or square in shape and adopts threaded connection, snap-fit ​​connection or plug-in connection. The interface is provided with electrical contact points for realizing electrical signal transmission between the internal signal processing module of the probe and the external data acquisition system, as well as a mechanical positioning structure for ensuring the accurate position and orientation of the probe when connected. The mechanical positioning structure adopts the method of positioning pin and positioning hole cooperation.

3. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 1, characterized in that, The probe body has multiple cavities inside, including a magnetization unit mounting cavity located at the front end or middle for mounting the magnetization unit, and a fixing device inside for fixing the magnetization unit by means of bolt fastening, slot fixing or elastic clamping. It also includes a magnetic sensor array mounting cavity distributed on the outer peripheral surface of the probe body, which is in the shape of a ring or arc. The cavity has multiple sensor mounting positions that match the size and shape of the magnetic sensor used, and an insulating isolation layer is provided between the sensor mounting positions. And a rectangular signal processing module mounting cavity located at the rear of the probe body, with a heat dissipation structure inside the cavity.

4. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 3, characterized in that, The insulating layer inside the mounting cavity of the magnetic sensor array is made of alumina ceramic with a thickness between 0.05 and 0.2 mm.

5. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 1, characterized in that, The magnetization unit is installed inside the probe body and mainly consists of a permanent magnet, a magnetic yoke, a fixing bracket, and an adjustment mechanism. The permanent magnets are high-performance neodymium iron boron permanent magnets, and each permanent magnet is processed into a cuboid or trapezoidal shape to meet the requirements of ring arrangement; The magnetic yoke is made of stacked cold-rolled silicon steel sheets in a circular shape. Its inner diameter is larger than the internal space diameter of the probe body used to install other components, and its outer diameter is determined according to the arrangement of permanent magnets and the required magnetic field coverage. The thickness of the silicon steel sheets is between 0.3 and 0.5 mm. The fixing bracket is used to firmly fix the permanent magnet to the magnetic yoke. It is made of non-magnetic material and has a slot on the bracket that matches the shape of the permanent magnet. The permanent magnet is embedded in the slot and fixed by bolts or buckles. The adjustment mechanism adjusts the strength and distribution of the magnetic field according to different oil and gas pipeline materials, sizes, and testing requirements; the adjustment mechanism adjusts the magnetic field strength by rotating the screw to change the relative position between the permanent magnet and the yoke.

6. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 5, characterized in that, Multiple permanent magnets are evenly distributed on the circumference of the yoke, and the spacing between adjacent permanent magnets remains consistent.

7. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 5, characterized in that, The adjustment mechanism also includes a dial and a pointer. The dial is fixed on the magnetic yoke, and the pointer is mounted on the rotating screw. When the rotating screw adjusts the relative position between the permanent magnet and the magnetic yoke, the pointer indicates the corresponding position on the dial.

8. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 1, characterized in that, The magnetic sensor is either a Hall sensor or a magnetoresistive sensor.

9. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 1, characterized in that, The probe body is also equipped with a status indicator light, which is connected to the microprocessor in the signal processing module to display the working status of the probe device.

10. The oil and gas pipeline sensor probe device based on weak magnetic field detection as described in claim 1, characterized in that, The protective shell is provided with multiple heat dissipation holes, which are evenly distributed in a circular shape and have a diameter between 1 and 3 mm.

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