Natural Gas Pipeline Corrosion Risk Mapping From 3D Multiphase Flow
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Solution Overview
Problem
Current methods for predicting internal corrosion in natural gas pipelines are limited by the complexity of multi-factor synergistic corrosion environments, particularly in gathering pipelines with varying transmission media and complex flow regimes, leading to inaccurate corrosion rate predictions and hindering effective risk-based management strategies.
Innovation Solution
A method involving three-dimensional multiphase flow simulations and a multi-factor synergistic corrosion model is employed to predict local corrosion rates, using a local corrosion failure criterion to identify pipeline segments at high risk of failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If in-line inspection (ILI) is used to assess internal pipeline corrosion, then measurement precision is improved, but cost increases significantly limiting widespread application
Solution Approach 1:
The patent creates a virtual copy of the pipeline system through three-dimensional multiphase flow simulation. Instead of physically inspecting every pipeline segment with expensive ILI tools, the system generates a digital replica that models flow patterns, corrosion risks, and pipeline behavior under various conditions, enabling cost-effective assessment while maintaining reasonable accuracy
Solution Approach 2:
The patent replaces the mechanical ILI inspection system with a computational simulation system. By substituting physical inspection tools with three-dimensional flow simulations and data processing algorithms, the system eliminates the need for costly mechanical intervention while providing comprehensive corrosion assessment capabilities
2Ease of manufacture
If empirical corrosion prediction models are used, then ease of manufacture is improved, but measurement precision deteriorates due to high dependence on specific historical corrosion data
Solution Approach 1:
The patent transforms the corrosion prediction approach by changing key parameters from static empirical values to dynamic simulation outputs. The system incorporates flow velocity, pressure gradients, temperature variations, and compositional changes as variable parameters that are continuously calculated through three-dimensional multiphase flow simulation, enabling accurate predictions without relying on historical data specific to particular pipelines
Solution Approach 2:
The patent creates a universal corrosion prediction model that can be applied across different pipeline configurations and operating conditions. The three-dimensional multiphase flow simulation framework provides a multi-functional platform that handles various flow regimes (gas, liquid, two-phase), different pipeline geometries, and diverse corrosion mechanisms (CO2 corrosion, sulfate-reducing bacteria, oxygen corrosion) within a single unified system
3Measurement precision
If mechanistic corrosion models are constructed to represent multi-factor synergistic corrosion environments, then measurement precision is improved, but device complexity increases making construction difficult in industrial settings
Solution Approach 1:
The patent segments the complex corrosion prediction problem into manageable components: (1) three-dimensional multiphase flow simulation to calculate flow parameters, (2) identification of key corrosion-influencing factors from simulation results, (3) separate mechanistic models for different corrosion mechanisms (CO2, SRB, O2), and (4) integration of these models to predict overall corrosion rates. This segmentation reduces construction complexity while maintaining comprehensive accuracy
Solution Approach 2:
The patent introduces an intermediary layer between the complex physical corrosion processes and the prediction model. The three-dimensional multiphase flow simulation acts as an intermediary that translates complex flow dynamics into simplified correlation inputs (flow velocity, pressure, temperature, composition) that can be processed by mechanistic corrosion models, bridging the gap between physical complexity and computational tractability
Data Source
AI summary
The present disclosure discloses a method for identifying the pipeline section with a high likelihood of internal corrosion failure. Through the three-dimensional multiphase flow simulation calculation of natural gas gathering and transportation pipeline, the flow parameters along the pipeline are obtained, and the data are collected; combined with the multiphase flow simulation parameters and data, the internal corrosion mechanism of the pipeline is clarified, the influencing factors of internal corrosion are identified, and the local corrosion rate along the pipeline is predicted by combining various corrosion influencing factors. Finally, the local corrosion failure criterion CRT is established, and the likelihood level of the internal corrosion failure is determined, which can be used to identify the high corrosion failure likelihood pipeline section of the natural gas gathering and transportation pipeline.