CN113252544B - Corrosion monitoring system and method for oil refining device - Google Patents
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Abstract
本发明提供了一种炼油装置腐蚀监测系统，包括：数据获取模块，用于获取炼油装置的M个监测对象的腐蚀监测数据，包括介质腐蚀速率、介质pH值、介质中的腐蚀性物质含量和设备壁厚；数据处理模块，用于基于获取的腐蚀监测数据得到每个腐蚀回路的评估监测数据，包括评估腐蚀速率、评估壁厚和剩余寿命；数据分析模块，用于将每个监测对象的工艺监测数据和评估监测数据分别与预设的工艺相关腐蚀完整性操作窗口和预设的设备相关腐蚀完整性操作窗口进行比较，并在确定监测数据没有位于对应的完整性操作窗口内时，进行预警。本发明还提供了一种炼油装置腐蚀监测方法。本发明能够有效的对炼油装置的腐蚀情况进行监控，降低监控成本，排除腐蚀隐患和防止腐蚀泄漏事故发生。
The invention provides a corrosion monitoring system for an oil refining plant, comprising: a data acquisition module for acquiring corrosion monitoring data of M monitoring objects of the oil refining plant, including the corrosion rate of the medium, the pH value of the medium, the content of corrosive substances in the medium and The wall thickness of the equipment; the data processing module is used to obtain the evaluation monitoring data of each corrosion circuit based on the obtained corrosion monitoring data, including the evaluation of the corrosion rate, the evaluation of the wall thickness and the remaining life; the data analysis module is used to The process monitoring data and the evaluation monitoring data are respectively compared with the preset process-related corrosion integrity operation window and the preset equipment-related corrosion integrity operation window, and when it is determined that the monitoring data is not located within the corresponding integrity operation window, carry out Warning. The invention also provides a corrosion monitoring method for an oil refining device. The invention can effectively monitor the corrosion situation of the oil refining device, reduce the monitoring cost, eliminate the hidden danger of corrosion and prevent the occurrence of corrosion leakage accidents.
Description
Technical Field
The invention belongs to the field of petrifaction, and particularly relates to a corrosion monitoring system and method for an oil refining device.
Background
Corrosion is the most important factor affecting the safe operation of oil refining equipment, and in the production management of oil refining enterprises, the corrosion management is an important component. In order to comprehensively manage and prevent corrosion, oil refining enterprises develop a series of related work related to material upgrading, process corrosion prevention, chemical analysis and equipment monitoring and detection, corresponding corrosion management and protection systems are all established, the corrosion prevention effect is effectively improved, the development of corrosion prevention work is guided, and the safe and stable operation of the device is guaranteed. However, the corrosion management system of the existing oil refining device mainly collects and manages data in the aspects of on-line monitoring, on-line thickness measurement, fixed-point thickness measurement, chemical analysis and the like, only realizes the functions of basic statistical analysis, alarm and the like, and simultaneously has the condition that various systems are mutually independent, so that the comprehensive analysis, evaluation and scientific corrosion prevention and control of various corrosion data cannot be realized.
Disclosure of Invention
In view of the above technical problems, embodiments of the present invention provide a corrosion monitoring system for an oil refining device, which comprehensively utilizes various corrosion-related parameters of an oil refining process to perform comprehensive intelligent monitoring on corrosion of the oil refining device.
The technical scheme adopted by the invention is as follows:
an embodiment of the present invention provides an oil refining apparatus corrosion monitoring system, including:
the system comprises a data acquisition module, a data processing module and a data processing module, wherein the data acquisition module is used for acquiring corrosion monitoring data of M monitoring objects of the oil refining device, each monitoring object comprises a corrosion loop and a corresponding process unit, the corrosion monitoring data comprises process monitoring data and equipment monitoring data, and the process monitoring data comprises a medium corrosion rate, a medium pH value and corrosive substance content in a medium; the device monitoring data comprises device wall thickness;
the data processing module is used for obtaining evaluation monitoring data of each corrosion loop based on the obtained corrosion monitoring data, wherein the evaluation monitoring data comprises an evaluation corrosion rate, an evaluation wall thickness and a residual life;
and the data analysis module is used for comparing the process monitoring data and the evaluation monitoring data of each monitored object with a preset process corrosion integrity operation window and a preset equipment corrosion integrity operation window respectively, and carrying out early warning when the monitoring data are determined not to be positioned in the corresponding integrity operation windows.
Another embodiment of the present invention provides a corrosion monitoring method for an oil refining apparatus, including:
s200, acquiring corrosion monitoring data of M monitoring objects of the oil refining device, wherein each monitoring object comprises a corrosion loop and a corresponding process unit, the corrosion monitoring data comprises process monitoring data and equipment monitoring data, and the process monitoring data comprises a medium corrosion rate, a medium pH value and corrosive substance content in a medium; the device monitoring data comprises device wall thickness;
s220, obtaining evaluation monitoring data of each corrosion loop based on the obtained corrosion monitoring data, wherein the evaluation monitoring data comprises an evaluation corrosion rate, an evaluation wall thickness and a residual life;
and S230, comparing the process monitoring data and the evaluation monitoring data of each monitored object with a preset process corrosion integrity operation window and a preset equipment corrosion integrity operation window respectively, and performing early warning when the monitoring data are determined not to be located in the corresponding corrosion integrity operation window.
Another embodiment of the present invention further provides a corrosion monitoring system for an oil refining apparatus, including: at least one processor; and a memory communicatively coupled to the at least one processor; wherein the memory stores instructions executable by the at least one processor, the instructions being arranged to perform the method as previously described.
The corrosion monitoring system and method for the oil refining device provided by the embodiment of the invention comprise the following steps of firstly, obtaining corrosion monitoring data of M monitoring objects of the oil refining device, wherein the corrosion monitoring data comprises medium corrosion rate, medium pH value and corrosive substance content in a medium related to a process, and equipment wall thickness and detection time related to equipment; then, obtaining evaluation monitoring data of each corrosion loop according to the obtained corrosion monitoring data, wherein the evaluation monitoring data comprises an evaluation corrosion rate, an evaluation wall thickness and a residual life; and then, comparing the process monitoring data and the evaluation monitoring data of each monitored object with a preset process corrosion integrity operation window and a preset equipment corrosion integrity operation window respectively, and performing early warning when the monitoring data are determined not to be positioned in the corresponding corrosion integrity operation window. Therefore, the oil refining device comprehensive corrosion monitoring and evaluating method and the intelligent early warning method are established in the embodiment of the invention in the two aspects of the process and the equipment, the operation window establishment aiming at the corrosion influence key factors in the two aspects of the process and the equipment is realized based on the principle of the integrity operation window, the loop management concept and the equipment reliability evaluating method are combined, and the comprehensive supervision contents such as corrosion monitoring, corrosion calculation, service life prediction, intelligent early warning and the like are formed.
Drawings
Fig. 1 is a schematic structural diagram of a corrosion monitoring system for an oil refining apparatus according to an embodiment of the present invention;
fig. 2 is a schematic flow chart of a corrosion monitoring system for an oil refining device according to an embodiment of the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
The oil refining device corrosion monitoring system provided by the embodiment of the invention is used for comprehensively and intelligently monitoring the corrosion condition of the oil refining device of a petrochemical enterprise. In the monitoring process, the oil refining device is divided into a plurality of corrosion loops according to a corrosion mechanism and a plurality of process units according to a process flow. The corrosion monitoring system for the oil refining device provided by the embodiment of the invention comprehensively manages various corrosion influence factors and results by analyzing data content required by corrosion control in the oil refining process; then, based on the combination of the integrity operation window and corrosion protection and equipment reliability technologies, establishing a typical loop corrosion control operation window of the oil refining device; meanwhile, a comprehensive corrosion monitoring method is established by utilizing a corrosion prediction method and an equipment reliability evaluation method, so that corrosion analysis, corrosion control, service life calculation, intelligent early warning and other unified and scientific management are realized, and a comprehensive and intelligent corrosion control effect is realized. The corrosion monitoring system for an oil refinery apparatus according to an embodiment of the present invention will be described in detail with reference to fig. 1.
As shown in fig. 1, an oil refining apparatus corrosion monitoring system according to an embodiment of the present invention includes: the device comprises a data acquisition module 1, a data processing module 2 and a data analysis module 3.
The data acquisition module 1 is configured to acquire corrosion monitoring data of M monitoring objects of the oil refining apparatus, where each monitoring object includes a corrosion loop and a corresponding process unit, the corrosion monitoring data includes process monitoring data and equipment monitoring data, and the process monitoring data includes a medium corrosion rate, a medium pH value, and a corrosive substance content in the medium; the equipment monitoring data includes equipment wall thickness and inspection time.
In embodiments of the present invention, the division of the etch loop and process unit may be determined based on existing methods. The corrosion rate and the pH value of the medium can be monitored by monitoring devices such as a corrosion rate monitoring instrument and a pH sensor which are arranged on monitoring points of the corrosion loop, and the data acquisition module 1 can be in communication connection with the monitoring devices to acquire related monitoring data. The corrosive substance content in the medium can be obtained by sampling and chemical analysis, and can be obtained by any existing method. In the embodiment of the invention, the wall thickness of the equipment can be obtained by the following two ways:
the method comprises the following steps that firstly, a plurality of key parts of a corrosion loop are used as monitoring points, and an online monitoring device such as an online thickness measuring sensor is arranged on the monitoring points to obtain the wall thickness of the corresponding position; the on-line thickness measuring sensor samples according to a preset sampling period, and sends sampling data and corresponding sampling time, namely detection time, to the data acquisition module 1.
And in the second mode, the thickness of the key part of the corrosion loop is manually measured by adopting a thickness gauge and the like, namely fixed-point thickness measurement is obtained. The spot thickness measurement may be performed at a predetermined period, for example, the predetermined period may be several months, for example, about 3 months.
The data processing module 2 is used for obtaining evaluation monitoring data of each corrosion loop based on the obtained corrosion monitoring data, wherein the evaluation monitoring data comprises an evaluation corrosion rate, an evaluation wall thickness and a residual life.
Specifically, in an embodiment of the present invention, the estimated corrosion rate of the corrosion loop may be determined by:
s100, calculating the long-term corrosion rate of each monitoring point in the corrosion loop i
Obtaining long-term corrosion rate sequence of monitoring points
Wherein, T0For the initial wall thickness of the monitoring point, TnWall thickness, t, of the monitoring point detected for the time of detection closest to the current evaluation timenAs the detection time nearest to the current time, TuThe time for putting the corrosion loop into service is the corresponding equipment operation time;
the long-term corrosion rate of the jth monitoring point in the corrosion loop i is represented by j, the value of j is 1 to n, n is the total number of the monitoring points of the corrosion loop i, and the value of i is 1 to M. The unit of time may be days. T is0Can be obtained by the basic data of the device, TnWall thickness, T, which can be detected by an on-line monitoring device or manuallyuThe method can be determined by the current time and the construction time of the equipment, and the construction time can also be obtained by basic data of the equipment.
S110, obtaining VL-max＝max(VL) And will VL-maxLong-term corrosion rate V as corrosion loop iLC。
S120, calculating short-term corrosion rate of each monitoring point in the corrosion loop i
Obtaining short-term corrosion rate sequence of monitoring points
Wherein, Tn1Wall thickness, t, of monitoring points detected for the next closest detection time to the current timen1The detection time next to the current time is obtained;
is the short term corrosion rate for the jth monitoring point in corrosion loop i.
S130, obtaining VS-max＝max(VS) And will VS-maxShort term etch rate V as etch loop iSC；
S140, obtaining the maximum corrosion rate V of the corrosion loop iC-max＝max(VL-max，VS-max)。
S150, calculating an adjustment factor
a is a preset coefficient, and the ratio of the average corrosion rate of online thickness measurement in a corrosion loop to the corrosion rate of online monitoring can be adoptedObtained or obtained empirically based on historical corrosion phenomena of the corrosion loop, e.g., the value range may be [0,1 ]]。
Wherein, TlossIs the sum of the wall thickness losses, t, of all monitoring points in the corrosion loop itotalIs the sum of the service time of all monitoring points in the corrosion loop i. The corrosion occurrence uniformity of the corresponding corrosion loop can be observed through R, and the larger the value is, the lower the corrosion uniformity of the loop is, and the local corrosion possibility is increased. R can be used for adjusting the corrosion rate of the loop on-line monitoring, and can also be used for increasing or decreasing corrosion monitoring points by defining the range of R.
S160, calculating the adjusted corrosion rate V of the corrosion loop iC-A＝Vm*F，VmThe corrosion rate of the medium corresponding to the corrosion loop i. Although the online monitoring directly reflects the corrosion rate of the material in the medium, the corrosion rate is different from the corrosion rate of the equipment, so that the corrosion rate of the corresponding equipment can be obtained by adaptively adjusting the corrosion rate of the medium.
S170, determining the predicted corrosion rate V of the corrosion loop i based on a preset corrosion rate prediction modelC-F. Since the arrangement of a large number of sensors leads to an increase in monitoring cost, the corrosion rate of some locations where no on-line monitoring device is installed can be obtained from the predicted corrosion rate of the corrosion loop by a preset corrosion rate prediction model. The preset corrosion rate prediction model is established and tested through a machine learning algorithm mainly through a large amount of historical corrosion factor data and a corresponding data set of corrosion rate data, and the establishment of an accurate corrosion rate prediction model is achieved. When the method is applied, only the data of the corrosion factors are needed to be input into the model, and the corrosion rate result under the corresponding corrosion factors can be predicted. The predetermined corrosion rate prediction model may be an existing model.
S180, determining an estimated corrosion rate V of the corrosion loop iC-E＝max(VC-max，VC-A，VC-F)。
Through steps S100 to S180, the estimated corrosion rate for each corrosion loop can be obtained. The evaluation corrosion rate of each corrosion loop comprehensively considers three types of corrosion rates, namely (1) the maximum corrosion rate obtained by detecting the wall thickness and the fixed-point thickness by an online monitoring device, (2) the corrosion rate adjustment representing the equipment corrosion rate obtained by the medium corrosion rate and (3) the corrosion rate obtained by predicting a corrosion rate prediction model, so that the corrosion rate used for evaluation can be more accurate by taking the maximum value of the three types of corrosion rates as the evaluation corrosion rate, and the evaluation effect is more accurate.
Further, the estimated wall thickness T of each corrosion loopE＝Tn-VC-E*(tpre-tn)，tpreIs the current evaluation time.
Further, the remaining life of each corrosion loop
TLThe limit wall thickness of the equipment corresponding to the corrosion loop. The limit wall thickness can adopt a corrosion allowance as a standard, and the limit wall thickness is calculated by taking the wall thickness of the equipment pipeline minus the corrosion allowance as the retired limit thickness; the ultimate wall thickness can also be calculated by relevant standards, such as ASME31.3, 31.4, 31.8, API653, storage tank, GB/T30513.
The data analysis module 3 is configured to compare the process monitoring data and the evaluation monitoring data of each monitored object with a preset process corrosion integrity operation window and a preset equipment corrosion integrity operation window, respectively, and perform early warning when it is determined that the monitoring data is not located in the corresponding corrosion integrity operation window.
In the embodiment of the present invention, the preset integrity operation window includes upper and lower limit values of each monitoring data, and the upper and lower limit values may be determined based on an actual situation. Specifically, the data analysis module 3 compares the medium corrosion rate, the medium pH value, and the corrosive substance content in the medium of each corrosion loop with a preset process corrosion integrity operation window, and if the corrosion rate, the medium pH value, and the corrosive substance content in the medium exceed corresponding upper and lower limit values, performs early warning, provides a targeted adjustment suggestion according to an overrun factor, and performs adjustment to restore the normal state. If the pipeline is not relieved after adjustment or is in an overrun state for a long time, suggestions on aspects of process anticorrosion adjustment, inspection and the like are provided, whether the overrun state causes equipment corrosion is judged according to a fixed point thickness measurement result of the same process equipment pipeline in the near term, and a comprehensive decision suggestion on equipment pipeline detection and material optimization is provided. And the data analysis module 3 respectively compares the estimated corrosion rate, the estimated wall thickness and the residual life of each corrosion loop with a preset equipment corrosion integrity operation window, and if the estimated corrosion rate, the estimated wall thickness and the residual life of each corrosion loop exceed corresponding upper and lower limit values, early warning is carried out and corresponding suggestions are given.
In summary, the corrosion monitoring system for the oil refining device provided by the embodiment of the invention establishes a comprehensive corrosion evaluation and intelligent early warning decision method for the oil refining device facing to the process and the equipment, realizes the establishment of an operation window aiming at corrosion influence key factors in the process and the equipment based on the principle of an integral operation window and combining a loop management concept and an equipment reliability evaluation method, and forms comprehensive management contents such as corrosion diagnosis, service life prediction, intelligent early warning and anticorrosion decision. By comprehensively utilizing data, the result of corrosion state prediction is used for corrosion assessment and management, the investment of monitoring and detecting cost can be effectively reduced, and support is provided for hidden danger identification. A scientific oil refining process corrosion supervision, prediction and decision method system is established, and the safe and full-stable long-period operation of the device can be effectively improved.
Another embodiment of the present invention provides a corrosion monitoring method for an oil refining apparatus. As shown in fig. 2, the method comprises the steps of:
s200, acquiring corrosion monitoring data of M monitoring objects of the oil refining device, wherein each monitoring object comprises a corrosion loop and a corresponding process unit, the corrosion monitoring data comprises process monitoring data and equipment monitoring data, and the process monitoring data comprises a medium corrosion rate, a medium pH value and corrosive substance content in a medium; the device monitoring data comprises device wall thickness;
s220, obtaining evaluation monitoring data of each corrosion loop based on the obtained corrosion monitoring data, wherein the evaluation monitoring data comprises an evaluation corrosion rate, an evaluation wall thickness and a residual life;
and S230, comparing the process monitoring data and the evaluation monitoring data of each monitored object with a preset process corrosion integrity operation window and a preset equipment corrosion integrity operation window respectively, and performing early warning when the monitoring data are determined not to be positioned in the corresponding process corrosion integrity operation window.
Further, the estimated corrosion rate of the corrosion loop is determined by:
s221, calculating the long-term corrosion rate of each monitoring point in the corrosion loop i
Obtaining long-term corrosion rate sequence of monitoring points
Wherein, T0For the initial wall thickness of the monitoring point, TnWall thickness, t, of the monitoring point detected for the time of detection closest to the current evaluation timenAs the detection time nearest to the current time, TuThe time for putting the corrosion loop into service is the corresponding equipment operation time; vjLThe long-term corrosion rate of the jth monitoring point in the corrosion loop i is defined as j, the value of j is 1 to n, n is the total number of the monitoring points of the corrosion loop i, and the value of i is 1 to M;
s222, obtaining VL-max＝max(VL) And will VL-maxLong-term corrosion rate V as corrosion loop iLC；
S223, calculating the short-term corrosion rate of each monitoring point in the corrosion loop i
Obtaining short-term corrosion rate sequence of monitoring points
Wherein, Tn1Detecting the next closest detection time to the current timeWall thickness of the monitoring point of (1), tn1The detection time next to the current time is obtained;
short-term corrosion rate for the jth monitoring point in corrosion loop i;
s224, obtaining VS-max＝max(VS) And will VS-maxShort term etch rate V as etch loop iSC；
S225, obtaining the maximum corrosion rate V of the corrosion loop iC-max＝max(VL-max，VS-max)；
S226, calculating an adjustment factor
a is a preset coefficient, and a is a preset coefficient,
wherein, TlossIs the sum of the wall thickness losses, t, of all monitoring points in the corrosion loop itotalThe sum of the operation time lengths of all monitoring points in the corrosion loop i;
s227, calculating the adjusted corrosion rate V of the corrosion loop iC-A＝Vm*F，VmThe medium corrosion rate corresponding to the corrosion loop i;
s228, determining the predicted corrosion rate V of the corrosion loop i based on a preset corrosion rate prediction modelC-F；
S229, determining the estimated corrosion rate V of the corrosion loop iC-E＝max(VC-max，VC-A，VC-F)。
Further, the estimated wall thickness T of the corrosion circuitE＝Tn-VC-E*(tpre-tn)，tpreIs the current evaluation time.
Further, the residual life of the corrosion loop
tpreFor the current evaluation time, TLThe limit wall thickness of the equipment corresponding to the corrosion loop.
The above steps can be realized by the above devices, and are not described herein again.
Another embodiment of the present invention further provides a corrosion monitoring system for an oil refining apparatus, including: at least one processor; and a memory communicatively coupled to the at least one processor; wherein the memory stores instructions executable by the at least one processor, the instructions being arranged to perform the method as previously described.
The above-mentioned embodiments are only specific embodiments of the present invention, which are used for illustrating the technical solutions of the present invention and not for limiting the same, and the protection scope of the present invention is not limited thereto, although the present invention is described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: any person skilled in the art can modify or easily conceive the technical solutions described in the foregoing embodiments or equivalent substitutes for some technical features within the technical scope of the present disclosure; such modifications, changes or substitutions do not depart from the spirit and scope of the embodiments of the present invention, and they should be construed as being included therein. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
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