CN119334281A - A sulfur deposition thickness measurement system and method based on ultrasonic detection - Google Patents
A sulfur deposition thickness measurement system and method based on ultrasonic detection Download PDFInfo
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Abstract
本申请提供一种基于超声波检测的硫沉积厚度测量系统和方法，所述系统包括一个或多个超声波探头，所述多个超声波探头分别安装在油气输送管道的不同位置，所述超声波探头用于以一定的频率向油气输送管道发射超声波信号，以及接收从油气输送管道的硫沉积层反射回的超声波信号；所述系统还包括数据采集与处理装置，用于分析超声波信号并计算硫沉积层的厚度。本申请能有效消除外界干扰，显著提升硫沉积厚度的测量精度，且具有广泛适用性，适用于多种金属材料表面的硫沉积检测。
The present application provides a sulfur deposition thickness measurement system and method based on ultrasonic detection, the system includes one or more ultrasonic probes, the multiple ultrasonic probes are respectively installed at different positions of the oil and gas pipeline, the ultrasonic probe is used to transmit ultrasonic signals to the oil and gas pipeline at a certain frequency, and receive ultrasonic signals reflected from the sulfur deposition layer of the oil and gas pipeline; the system also includes a data acquisition and processing device for analyzing the ultrasonic signal and calculating the thickness of the sulfur deposition layer. The present application can effectively eliminate external interference, significantly improve the measurement accuracy of sulfur deposition thickness, and has wide applicability, and is suitable for sulfur deposition detection on the surfaces of various metal materials.
Description
Technical Field
The application relates to the technical field of ultrasonic nondestructive testing, in particular to a sulfur deposition thickness measuring system and method based on ultrasonic testing.
Background
In the development of oil and gas fields, the accuracy of sulfur deposit thickness detection in a conveying pipeline is important. The method not only affects the evaluation of equipment corrosion and maintenance requirements, but also relates to the evaluation of economic benefits and decision adjustment, and has important significance for the formulation of oil extraction processes in oil and gas field development.
The thickness of sulfur deposits in the oil delivery conduit directly affects the operating conditions of the equipment and the efficiency of oil recovery, including maintenance planning, safety of equipment operation, and optimization of production strategies. In addition, the production process is adjusted according to the sulfur deposition condition, proper technical means are selected, the recovery ratio can be improved, the operation cost is reduced, and equipment which needs cleaning and maintenance can be timely identified by monitoring the sulfur deposition thickness, so that the downtime is reduced, the operation efficiency is improved, and if the sulfur deposition thickness in the conveying pipeline is detected inaccurately, the resource waste, the production efficiency is low, and even the equipment damage and the safety accident are caused.
The main prediction methods for detecting sulfur deposit thickness by ultrasonic waves commonly used at present comprise detection based on nuclear magnetic resonance and dust concentration prediction. For example, patent document CN202410536171.X, a characterization method for rock sulfur deposition injury rate and sulfur deposition position discrimination based on nuclear magnetic resonance and a scheme shown in CN202110132164.X, a sulfur deposition testing device for sulfur-containing natural gas gathering and transportation pipeline, which have the defects of high cost, expensive equipment, complex operation, high requirements for detection environment and incapability of being used under high temperature and high pressure conditions due to the fact that the detection of dust concentration has indirection, and the result of estimating sulfur deposition by measuring the dust concentration may not be accurate enough, low sensitivity and possibly unsatisfactory detection effect when the dust concentration is low or unevenly distributed.
Disclosure of Invention
In view of the above, the application provides a sulfur deposition thickness measuring system and method based on ultrasonic detection, which have strong applicability, simple operation and more accurate detection results.
In order to achieve the above purpose, the technical scheme adopted by the application is as follows:
in a first aspect, the present application provides a sulfur deposit thickness measurement system based on ultrasonic detection, comprising one or more ultrasonic probes respectively mounted at different positions of an oil and gas conveying pipeline, the ultrasonic probes being configured to transmit ultrasonic signals to the oil and gas conveying pipeline at a certain frequency and to receive ultrasonic signals reflected back from a sulfur deposit layer of the oil and gas conveying pipeline;
the system further comprises a data acquisition and processing device for analyzing the ultrasonic signals and calculating the thickness of the sulfur deposit.
Optionally, the sulfur deposit thickness measuring system further includes:
The three-dimensional reconstruction device is used for generating a three-dimensional thickness field (x, y, d) according to sulfur deposition thickness data of a plurality of angles by utilizing an interpolation algorithm and a least square method, wherein x is used for representing a transverse vector of the ultrasonic probe at a spatial position, y is used for representing a longitudinal vector of the ultrasonic probe at the spatial position, and d is used for representing a sulfur deposition thickness vector.
Optionally, the sulfur deposit thickness measurement system further includes an algorithm correction module, the algorithm correction module further comprising:
The denoising module is used for carrying out frequency domain analysis by adopting wavelet transformation and Fourier transformation and filtering high-frequency noise in the thickness detection result;
And the multi-reflection correction module is used for calculating a correction factor of multi-reflection according to the propagation characteristics of the ultrasonic signals and correcting the thickness of sulfur deposit according to the correction factor.
Optionally, the sulfur deposit thickness measuring system further includes:
The automatic data analysis module is used for analyzing the change trend of the sulfur deposition thickness along with time by using a linear regression statistical method according to the detection result stored for a long time;
and the alarm module is used for automatically triggering an alarm function when the detected sulfur deposition thickness value reaches or exceeds a critical thickness value.
Optionally, the sulfur deposit thickness measuring system further includes:
The wireless data transmission module is used for transmitting the measurement data to the remote equipment or the cloud;
And the display module is used for displaying the measurement result in real time.
In a second aspect, the present application provides a sulfur deposit thickness measuring method based on ultrasonic detection, the method being applied to a system having one or more ultrasonic probes respectively installed at different positions of an oil and gas transmission pipe, the method comprising:
a. The ultrasonic probe transmits ultrasonic signals to the oil and gas transmission pipeline at a certain frequency;
b. The ultrasonic probe receives ultrasonic signals reflected back from a sulfur deposition layer of the oil gas conveying pipeline and sends the ultrasonic signals to the data acquisition and processing device;
c. The data acquisition and processing device acquires and utilizes the reflected ultrasonic signals to calculate the thickness of sulfur deposit in the oil and gas pipeline, and the specific calculation method comprises the following steps:
Setting the propagation speed of ultrasonic waves in a sulfur deposition layer as V sulfur, the propagation time as t reflection, and the thickness d sulfur of the sulfur deposition layer as a calculation formula:
Where t reflection is the time delay from transmission to receipt of the reflected signal.
Optionally, the sulfur deposit thickness measuring method further includes:
q1. generating a three-dimensional thickness field (x, y, d) by utilizing sulfur deposition layer thickness data of a plurality of angles and utilizing an interpolation algorithm and a least square method, wherein x is used for representing a transverse vector of an ultrasonic probe at a spatial position, y is used for representing a longitudinal vector of the ultrasonic probe at the spatial position, and d is used for representing a sulfur deposition thickness vector, and specifically comprises the following steps:
using cubic spline interpolation, for a one-dimensional case, the cubic spline interpolation function can be expressed as:
Where Si (x) is a spline function for each interval, typically in the form of:
Si(x)＝ai+bi(x-xi)+ci(x-xi)2+di(x-xi)3
By setting the boundary conditions and continuity conditions, the values of ai, bi, ci, and di can be solved.
The least square method model is as follows:
d(x,y)=A·x
Where d (x, y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is the vector containing the coordinate information.
The objective of the least squares method is to minimize the following objective function:
The optimal parameter estimation can be obtained by constructing a jacobian matrix J and performing minimization calculation;
for each (x, y) point, the corresponding d value can be calculated through interpolation, and finally, a three-dimensional thickness field (x, y, d) is obtained.
Optionally, the sulfur deposit thickness measuring method further includes:
q2. adopts wavelet transformation and Fourier transformation to carry out frequency domain analysis, and filters high-frequency noise in the thickness detection result.
Optionally, the sulfur deposit thickness measuring method further includes:
q3. calculating a correction factor of the multiple reflections according to the propagation characteristics of the ultrasonic signals, and correcting the thickness of sulfur deposition according to the correction factor;
the correction factor for multiple reflections is calculated, typically based on geometry and media characteristics, expressed as:
Wherein R i is the influence degree of the ith reflection, and n is the reflection times.
Then, the thickness calculation correction is carried out, and a correction factor K is introduced into a final thickness calculation formula to obtain a correction
The thickness d sulfur,corrected after the front is:
the beneficial effects of the application are as follows:
the high-precision measurement is realized by adopting an advanced ultrasonic technology and combining a high-frequency signal and a signal processing algorithm, the measurement precision of the sulfur deposition thickness is obviously improved, and the limitation of the traditional method in a complex environment is overcome.
The adaptability is improved by designing a set of detection system which is suitable for various environmental conditions, and the detection system can effectively work under high temperature, high pressure and dust environments, and the reliability and the effectiveness of detection results are ensured.
The operation flow is simplified, the convenience of operation is improved, and the professional requirements on operators are reduced by optimizing the design of equipment and automatically controlling the equipment, so that the detection process is more efficient and user-friendly.
The maintenance cost is reduced, the dependence on high-precision logging equipment is reduced, the economical and effective deposition thickness measurement is realized by utilizing the ultrasonic detection technology, and the equipment maintenance and operation cost is reduced.
And the data processing efficiency is improved, namely the timely monitoring of the sulfur deposition state is realized through real-time data acquisition and rapid processing, the timely adjustment of the production strategy is facilitated, and the production flow is optimized.
And errors and trial-and-error cost are reduced, namely maintenance delay or excessive cleaning caused by judgment errors are avoided through accurate thickness measurement, trial-and-error time and cost are reduced, and operation efficiency is improved.
The method supports scientific decision-making, provides accurate sulfur deposition thickness data, provides solid basis for production decision-making of the oil-gas field, helps a management layer to make more reasonable maintenance and production strategies, and improves overall economic benefit.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a sulfur deposit thickness measuring system based on ultrasonic detection;
FIG. 2 is a block diagram of a sulfur deposit thickness measuring system based on ultrasonic detection according to the present application;
FIG. 3 is a block diagram of an algorithm correction module of the present application;
FIG. 4 is a flow chart of a sulfur deposit thickness measurement method based on ultrasonic detection in accordance with the present application;
FIG. 5 is a graph comparing the thickness of a sulfur deposit layer before and after calibration by an algorithm correction module according to the present application.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present application more apparent, the technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application, and it is apparent that the described embodiments are some embodiments of the present application, but not all embodiments of the present application.
The application realizes accurate measurement of the thickness of the sulfur deposition layer by utilizing the propagation characteristic of ultrasonic waves in the pipeline. Typically, ultrasonic detection devices are typically comprised of an ultrasonic transmitter, receiver, and control system.
The high-frequency sound wave is sent out by the transmitter, when the sound wave encounters sulfur deposition, reflection occurs, and the receiver receives the reflected wave and measures the return time of the reflected wave, so that the deposition thickness is calculated.
In order to ensure the efficiency and stability of the ultrasonic detection system, the implementation environment should satisfy the following conditions:
the temperature range is-20 ℃ to 80 ℃ so as to adapt to different industrial environments.
The pressure range is 0-10 MPa, and the system is ensured to work normally under the high pressure condition.
Corrosion protection, namely, the equipment shell is made of an anti-corrosion material, so that the durability in a chemical environment is ensured.
The ultrasonic detection device of the present application is an ultrasonic probe, as shown in fig. 1 and 2, in a first aspect, the present application provides a sulfur deposit thickness measuring system based on ultrasonic detection, comprising one or more ultrasonic probes 210, wherein the plurality of ultrasonic probes 210 are respectively installed at different positions of an oil gas conveying pipeline, and the ultrasonic probes are used for transmitting ultrasonic signals to the oil gas conveying pipeline at a certain frequency and receiving ultrasonic signals reflected from a sulfur deposit layer of the oil gas conveying pipeline.
Initial installation of equipment
As shown in fig. 1, suitable mounting points are selected based on the structural features of the apparatus and the predicted area of sulfur deposition. For long distance pipelines, it is recommended to install an ultrasonic probe 210 at regular intervals of 0.5m, and the ultrasonic probe 210 is firmly installed on the outer wall of the oil and gas pipeline by using a magnetic bracket or a bolt clamp. For high temperature, high pressure pipes, a protective housing may be employed to protect the ultrasound probe 210 from the external environment.
The ultrasonic probe 210 generally includes an ultrasonic transmitting device and an ultrasonic receiving device, the ultrasonic transmitting device including:
1) The piezoelectric crystal sensor adopts piezoelectric material lithium tantalate as an ultrasonic emission source, and the piezoelectric crystal is excited by an electric signal to generate high-frequency ultrasonic waves. The frequency ranges from 5MHz to 20MHz, and the frequency is selected and adjusted according to the thickness of sulfur deposit and the acoustic properties of pipeline materials.
2) And the driving circuit is used for providing high-voltage short pulse current to excite the piezoelectric crystal, so that the emitted ultrasonic signal has enough penetrating power. The peak voltage of the pulse current is 100V to 200V, and the pulse width is hundreds of nanoseconds to match the high frequency signal of the ultrasonic wave.
The ultrasonic receiving device is matched with the transmitting device and is responsible for receiving ultrasonic signals reflected from the sulfur deposition layer. The concrete composition is as follows:
1) Piezoelectric crystal receiver-similar to the transmitting device, the receiver uses a high sensitivity lithium tantalate piezoelectric material to convert the ultrasonic signal into an electrical signal.
2) And the pre-amplifier is used for carrying out preliminary amplification on the received signal because the received reflected signal is weaker, and the signal gain can reach 60dB so as to improve the signal-to-noise ratio.
3) And the band-pass filter is used for filtering noise in the ultrasonic signal, only retaining effective signals in a target frequency range and ensuring measurement accuracy.
In one embodiment, the ultrasonic transmission device Olympus 38DL PLUS ultrasonic thickness meter may be used to transmit signals, and the frequency of the pulsed short wave signal is set to 1-5MHz, so as to avoid signal interference caused by continuous transmission. The transmitted pulse signal can be expressed as:
s(t)=A·sin(2πft)
wherein A is the signal amplitude, f is the frequency, and t is the time.
The ultrasonic receiving device selects a quartz piezoelectric transducer to capture the signal reflected back from the sulfur deposit. Ultrasonic receiver Olympus V506. The signal is gain processed by a pre-amplifier Analog DEVICES AD620,620 to increase the signal strength and reduce noise interference.
The AD620 adopts a differential amplifier configuration, so that common mode noise can be effectively suppressed. The input signal is passed through two inputs (positive and negative inputs) and the amplifier amplifies only the differential part of the signal and suppresses the co-existing noise signal.
Gain setting, the gain of AD620 can be set by external resistance, the gain formula is:
Where RG is the resistance connected between the amplifier pins. Selecting the appropriate RG value can achieve the required gain to amplify the weak reflected signal to a processable level.
The low noise characteristic, the AD620 is designed to have a low input noise characteristic, and can reduce noise generated by itself while amplifying a signal. This is particularly important for weak signal processing, and can ensure signal definition and reliability.
The high input impedance, 2mΩ, of the AD620 enables direct connection to the sensor or probe without significantly affecting the output of the signal source. The high input impedance helps to reduce signal attenuation, thereby preserving more of the original signal characteristics.
The output signal is processed, gain processed, and the output signal of AD620 is amplified to a level suitable for subsequent processing, and is typically output to an analog-to-digital converter (ADC) for digital processing. The signal after gain has higher amplitude, so that the subsequent data analysis and processing are convenient.
The sulfur deposit thickness measuring system further includes a data acquisition and processing device 220 for analyzing the ultrasonic signals and calculating the thickness of the sulfur deposit layer. The data acquisition and processing device 220 includes:
1) A high-speed ADC (analog-to-digital converter) for converting analog ultrasonic signals into digital signals, the ADC sampling rate being not lower than 50MHz to ensure that fine variations of the ultrasonic signals are captured.
2) And the FPGA/DSP processing unit is used for rapidly processing the time delay and amplitude change of the reflected signals and calculating the sulfur deposition thickness. The FPGA (e.g., xilinx Spartan-6) is responsible for processing data in parallel at high speed and the DSP is used to perform complex algorithms such as denoising, filtering, and feature extraction of the reflected signal.
The specific calculation method of the sulfur deposition layer comprises the following steps:
Setting the propagation speed of ultrasonic waves in a sulfur deposition layer as V sulfur, the propagation time as t reflection, and the calculation formula of the thickness d sulfur of sulfur deposition as follows:
Where t reflection is the time delay from transmission to receipt of the reflected signal.
The scheme has the advantages of high precision, real-time dynamic monitoring, strong adaptability and the like, provides important data support for equipment maintenance, effectively reduces the failure rate and improves the production efficiency.
Further, the data acquisition and processing device 220 may be further configured to analyze the signal amplitude:
the amplitude of the reflected signal is analyzed, and the result of the time delay calculation is verified in combination with the intensity decay of the reflected signal. For example, the signal processing module Texas Instruments TMS and the DSP 320 can be selected to perform amplitude analysis, and the analysis formula is as follows:
Where a reflected is the received reflected signal amplitude, a incident is the transmitted signal amplitude, α is the attenuation coefficient of the sulfur layer, and d sulfurd is the sulfur deposition thickness.
Optionally, as shown in fig. 2, the sulfur deposit thickness measuring system further includes:
Three-dimensional reconstruction means 230 for generating a three-dimensional thickness field (x, y, d) from the sulfur deposit thickness data for a plurality of angles using an interpolation algorithm and a least squares method, the x being used to characterize a lateral vector of the ultrasonic probe at a spatial location, the y being used to characterize a longitudinal vector of the ultrasonic probe at the spatial location, and the d being used to characterize the sulfur deposit thickness vector.
By collecting thickness data of a plurality of angles and combining a three-dimensional reconstruction algorithm interpolation algorithm and a least square method, the system can generate a three-dimensional thickness distribution map of a sulfur deposit layer in equipment, and provides more comprehensive reference data for equipment maintenance personnel.
The method comprises the following specific steps:
1) Data acquisition and arrangement
Thickness data measured from different probes are recorded as (x i,yi,zi,di), where (x i,yi,zi) is the spatial coordinates of the probe and d i is the corresponding thickness value.
2) Interpolation algorithm
To generate a continuous thickness field, cubic spline interpolation may be used.
Cubic spline interpolation:
For the one-dimensional case, the cubic spline interpolation function can be expressed as:
Wherein S i (x) is a spline function for each interval, typically in the form of:
Si(x)＝ai+bi(x-xi)+ci(x-xi)2+di(x-xi)3
By setting the boundary conditions and continuity conditions, the values of ai, bi, ci, and di can be solved.
3) Least square method
In performing multidimensional data interpolation, a least squares method is typically used to fit the thickness field.
Least squares model:
The set model is as follows:
d(x,y)=A·x
Where d (x, y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is the vector containing the coordinate information.
The objective of the least squares method is to minimize the following objective function:
By constructing the jacobian matrix J and performing a minimization calculation, an optimal parameter estimate can be obtained.
4) Integration and generation of thickness fields
Combining the interpolation and fitting results, a three-dimensional thickness field (x, y, d) can be generated. For each (x, y) point, the corresponding d value can be calculated through interpolation, and finally, the three-dimensional distribution map of the sulfur deposit layer is obtained.
Optionally, the sulfur deposit thickness measurement system further includes an algorithm correction module 240, as shown in fig. 3, the algorithm correction module 240 further includes:
the denoising module 241 is configured to perform frequency domain analysis by using wavelet transform and fourier transform, and filter high-frequency noise in the thickness detection result;
1 wavelet transform
Signal decomposition, using wavelet transform to decompose the original signal into sub-signals of different frequencies. A suitable wavelet based Daubechies wavelet is selected for multi-layer decomposition.
Where c jk is the wavelet coefficients and ψ jk (t) is the wavelet basis function.
Then, a threshold processing is applied to the wavelet coefficient, and the coefficient lower than the set threshold is removed to eliminate noise, and the common threshold methods are a soft threshold and a hard threshold.
Soft threshold:
Hard threshold:
and reconstructing the signals, namely reconstructing the denoised coefficients into denoised signals through inverse wavelet transformation.
Wherein, Is the denoised coefficient.
2FFT (fast Fourier transform)
And frequency domain transforming, namely applying FFT to the denoised signal to transform the signal from the time domain to the frequency domain.
Where N is the signal length and x (N) is the time domain signal.
Filtering, in which a band-pass filter is applied in the frequency domain to filter out unwanted frequency components (such as high frequency noise and low frequency interference). The filtered frequency domain signal is converted back to the time domain by an inverse FFT.
The multiple reflection correction module 242 is used for calculating a correction factor of multiple reflection according to the propagation characteristics of the ultrasonic signal and correcting the thickness of the sulfur deposition layer according to the correction factor.
And establishing an ultrasonic propagation model, calculating correction factors of multiple reflections, and introducing the correction factors into thickness calculation. The reflection times correction algorithm firstly establishes an ultrasonic wave propagation model, and considers reflection and propagation characteristics of signals in different media. It is assumed that the ultrasonic signal undergoes multiple reflections during propagation.
The signal decomposition is performed by separating the main reflected signal from the multiple reflected signal by signal processing techniques such as pulse compression.
The correction factor for multiple reflections is calculated, typically based on geometry and media characteristics, expressed as:
Wherein R i is the influence degree of the ith reflection, and n is the reflection times.
Then, performing thickness calculation correction, and introducing correction factors into a final thickness calculation formula:
In multiple reflection correction, the value of the degree of influence R i is typically determined by experimental data and a signal propagation model. For example, the intensity of the reflected signal can be obtained by analyzing sulfur deposited samples of different thickness, creating a model, recording the intensity decay for each reflection, and measuring under different conditions. Experimental data can help define the empirical value of R i to more accurately correct for the effects of multiple reflections on the measurement.
Specific examples are:
standard sulfur deposit samples of different thicknesses were selected to ensure that their thickness ranges covered the intended application scenario. Under the same environmental conditions, measurements were made using an ultrasonic device. A plurality of transmitting and receiving units are provided to ensure uniform coverage of the signal. The ultrasonic propagation time and the reflected signal amplitude of each sample were recorded. Multiple repeated measurements are suggested to improve data reliability.
And analyzing the signal amplitude measured each time, and calculating the reflection intensity and time delay under different thicknesses. And establishing the relation of the reflection intensity changing along with the thickness. Data fitting was then performed to obtain the empirical value of R i using the following polynomial regression analysis method:
A reflected＝a0+a1·d+a2·d2+…+an·dn is a polynomial regression formula, wherein A reflected is the reflected signal amplitude, d is the sulfur deposit thickness, a 0,a1,…,an is the polynomial coefficient, and n is the order of the polynomial.
As shown in fig. 5, the verification result of the thickness of the sulfur deposit layer is compared with the actual measurement result, and the model parameters are adjusted to optimize the correction effect of the reflection times.
Optionally, the sulfur deposit thickness measuring system further includes:
the automatic data analysis module 250 is configured to analyze a trend of the sulfur deposit thickness over time by using a linear regression statistical method according to the detection result stored for a long time, and specifically includes:
1. ) Long term data storage
And (3) data acquisition, wherein after each ultrasonic measurement, the system records measurement results, including information such as a time stamp, a sulfur deposition thickness d sulfur, equipment states and the like.
The data format, the measurement result is stored in CSV structured format, which ensures the data readability and easy subsequent analysis.
And the storage medium is used for selecting cloud storage, so that the data security and long-term availability are ensured.
And (5) data backup is carried out periodically to prevent data loss and damage.
2) Automatic trend analysis
And automatically analyzing the data stored for a long time to generate a trend curve of the thickness change of the sulfur deposit. And analyzing the change trend of the sulfur deposit thickness along with time by adopting linear regression analysis and a linear regression statistical method. Future thickness variations are predicted by fitting a straight line.
Thickness variation calculation, by calculating the thickness difference between each measurement, time-series thickness variation data is generated.
And a thickness change curve chart is generated by using the graphic tool Matplotlib in visual display, so that maintenance personnel can check the trend conveniently.
The alarm module 260 is configured to automatically trigger an alarm function when the detected sulfur deposit thickness value reaches or exceeds a critical thickness value, and specifically includes:
Setting critical thickness, setting critical thickness value, and once the thickness reaches or exceeds the value, automatically triggering an alarm function by the system.
And the alarm mechanism reminds maintenance personnel to process in time in a mode of e-mail, short message or system notification and the like.
Through long-term data storage and automatic trend analysis, the change condition of sulfur deposition can be effectively monitored, maintenance personnel can be helped in time to find problems, equipment faults and downtime are reduced, and production efficiency and safety are improved.
Optionally, the sulfur deposit thickness measuring system further includes:
The wireless data transmission module 270 is configured to transmit the measurement data to a remote device or a cloud;
specifically, the LoRa communication module can be adopted to realize data transmission in medium and long distances, and the transmission distance of the LoRa module can reach several kilometers, so that the method is suitable for complex industrial environments.
And, upload the measurement data to the cloud through wireless data transmission module 270, the user can be through PC or mobile device remote access data, real-time supervision equipment behavior.
And the display module 280 is used for displaying the measurement result in real time.
The display module 280 displays the measurement result in real time through a Liquid Crystal Display (LCD) or a touch screen, and adjusts the measurement parameters through a control interface. The method specifically comprises the following steps:
1) And the emission frequency is adjusted, namely, the user can adjust the frequency of ultrasonic emission according to equipment materials and sulfur deposition characteristics so as to obtain the optimal reflection effect.
2) Measurement mode-providing two modes, a single measurement and a continuous measurement, the continuous measurement being used for dynamically monitoring sulfur deposit changes, the single measurement being suitable for periodic equipment inspection.
3) And the data recording and playback, wherein the display module supports the functions of historical data query and playback, and a user can trace back past measurement results and analyze the change trend of sulfur deposition.
The system can adapt to various industrial environments, can work normally under high-temperature, high-pressure and corrosive environments, is particularly suitable for long-term monitoring of petroleum, natural gas and chemical production lines, can realize thickness measurement of a sulfur deposit layer with micron-scale precision through high-speed signal processing and multiple reflection correction algorithms, supports continuous measurement and remote data transmission, enables a user to grasp the running state of equipment in real time, discovers sulfur deposit problems in the equipment in time, avoids shutdown maintenance, and can reconstruct three-dimensional distribution of sulfur deposit in the equipment through a multipoint measurement technology, so that more comprehensive information is provided for equipment maintenance.
In a second aspect, as shown in fig. 4, the present application provides a sulfur deposit thickness measuring method based on ultrasonic detection, which is applied to a system having one or more ultrasonic probes installed at different positions of an oil and gas transmission pipe, respectively, the sulfur deposit thickness measuring method comprising:
s401, the ultrasonic probe transmits ultrasonic signals to the oil gas transmission pipeline at a certain frequency;
S402, the ultrasonic probe receives ultrasonic signals reflected back from a sulfur deposition layer of the oil gas conveying pipeline and sends the ultrasonic signals to the data acquisition and processing device;
S403, the data acquisition and processing device acquires and utilizes the reflected ultrasonic signals to calculate the thickness of sulfur deposit in the oil gas pipeline, and the specific calculation method comprises the following steps:
Setting the propagation speed of ultrasonic waves in a sulfur deposition layer as V sulfur, the propagation time as t reflection, and the calculation formula of the thickness d sulfur of sulfur deposition as follows:
Where t reflection is the time delay from transmission to receipt of the reflected signal.
The scheme has the advantages of high precision, real-time dynamic monitoring, strong adaptability and the like, provides important data support for equipment maintenance, effectively reduces the failure rate and improves the production efficiency.
Optionally, the sulfur deposit thickness measuring method further includes:
q1. generating a three-dimensional thickness field (x, y, d) by utilizing sulfur deposition thickness data of a plurality of angles and utilizing an interpolation algorithm and a least square method, wherein x is used for representing a transverse vector of an ultrasonic probe at a spatial position, y is used for representing a longitudinal vector of the ultrasonic probe at the spatial position, and d is used for representing a sulfur deposition thickness vector, and specifically comprises the following steps:
using cubic spline interpolation, for a one-dimensional case, the cubic spline interpolation function can be expressed as:
Wherein S i (x) is a spline function for each interval, typically in the form of:
Si(x)＝ai+bi(x-xi)+ci(x-xi)2+di(x-xi)3
By setting the boundary conditions and continuity conditions, the values of a i、bi、ci, and d i can be solved.
The least square method model is as follows:
d(x,y)=A·x
Where d (x, y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is the vector containing the coordinate information.
The objective of the least squares method is to minimize the following objective function:
The optimal parameter estimation can be obtained by constructing a jacobian matrix J and performing minimization calculation;
for each (x, y) point, the corresponding d value can be calculated through interpolation, and finally, a three-dimensional thickness field (x, y, d) is obtained.
By collecting thickness data of a plurality of angles and combining a three-dimensional reconstruction algorithm interpolation algorithm and a least square method, the system can generate a three-dimensional thickness distribution map of a sulfur deposit layer in equipment, and provides more comprehensive reference data for equipment maintenance personnel.
Optionally, the sulfur deposit thickness measuring method further includes:
q2. adopts wavelet transformation and Fourier transformation to carry out frequency domain analysis, and filters high-frequency noise in the thickness detection result.
1 Wavelet transform
Signal decomposition, using wavelet transform to decompose the original signal into sub-signals of different frequencies. A suitable wavelet based Daubechies wavelet is selected for multi-layer decomposition.
Where c jk is the wavelet coefficients and ψ jk (t) is the wavelet basis function.
Then, a threshold processing is applied to the wavelet coefficients to remove coefficients below a set threshold to eliminate noise. Common thresholding methods are soft and hard thresholding.
Soft threshold:
Hard threshold:
and reconstructing the signals, namely reconstructing the denoised coefficients into denoised signals through inverse wavelet transformation.
Wherein, Is the denoised coefficient.
2FFT (fast Fourier transform)
And frequency domain transforming, namely applying FFT to the denoised signal to transform the signal from the time domain to the frequency domain.
Where N is the signal length and x (N) is the time domain signal.
Filtering, in which a band-pass filter is applied in the frequency domain to filter out unwanted frequency components (such as high frequency noise and low frequency interference). The filtered frequency domain signal is converted back to the time domain by an inverse FFT.
Optionally, the sulfur deposit thickness measuring method further includes:
q3. calculates correction factors of multiple reflections according to the propagation characteristics of ultrasonic signals, and corrects the thickness of the sulfur-deposited layer according to the correction factors, specifically:
and establishing an ultrasonic propagation model, calculating correction factors of multiple reflections, and introducing the correction factors into thickness calculation. The reflection times correction algorithm firstly establishes an ultrasonic wave propagation model, and considers reflection and propagation characteristics of signals in different media. It is assumed that the ultrasonic signal undergoes multiple reflections during propagation.
The signal decomposition is performed by separating the main reflected signal from the multiple reflected signal by signal processing techniques such as pulse compression.
The correction factor for multiple reflections is calculated, typically based on geometry and media characteristics, expressed as:
where Ri is the influence degree of the ith reflection, and n is the number of reflections.
Then, performing thickness calculation correction, and introducing correction factors into a final thickness calculation formula:
As shown in fig. 5, the verification result of the thickness of the sulfur deposit layer is compared with the actual measurement result, and the model parameters are adjusted to optimize the correction effect of the reflection times.
The method for detecting the sulfur deposition thickness based on ultrasonic waves has strong real-time performance, can rapidly detect on site, and is suitable for dynamic monitoring. The application is wide, and the method is applicable to various materials and environmental conditions, and is not limited by temperature and pressure. The cost is lower, the equipment is relatively cheap, the maintenance cost is low, and the method is suitable for large-scale application. Under the insufficient conditions of nuclear magnetic resonance and dust concentration detection methods, the ultrasonic detection method becomes a more effective choice due to the instantaneity, wide applicability and lower cost, and particularly in complex oilfield environments, can provide more accurate and reliable sulfur deposition thickness measurement.
Furthermore, the scheme of the application can also carry out a calibration process before actually carrying out the thickness measurement of the ultrasonic sulfur deposition layer, and specifically comprises the following steps:
1. And (3) empty pipeline calibration, namely carrying out no-load measurement when the equipment is not operated, and obtaining sound velocity and basic echo data of the pipeline material. In the empty tube state, the emitted ultrasonic wave can penetrate directly to the tube wall and generate strong reflected signals.
2. And (3) calibrating a standard sample, namely measuring on the standard sulfur deposition sample to obtain ultrasonic reflection characteristics of sulfur layers with different thicknesses, and storing the ultrasonic reflection characteristics in a system as reference data during measurement.
Furthermore, in order to more comprehensively monitor the thickness distribution of the sulfur deposit layer, the scheme of the application also supports the arrangement of a plurality of ultrasonic probes, a plurality of ultrasonic probes are simultaneously arranged at different positions of the oil gas pipeline to form a grid layout, each probe independently transmits ultrasonic signals and receives reflected waves, and the thickness of the sulfur deposit layer at different positions is calculated by measuring echo time.
Furthermore, the system of the application can also realize the functions of automatic calibration, fault diagnosis, maintenance and the like, and is specifically as follows:
1 automatic calibration function
1) Periodic reference measurement
The speed of sound varies under different temperature and pressure conditions, affecting the propagation speed of the ultrasonic signal. Thus, periodic reference measurements can help correct the speed of sound in a timely manner.
Reference sample preparation, at initial system setup, a standard sulfur deposit sample of known thickness was selected as the reference for calibration.
And (3) timing measurement, wherein the system is set to automatically perform reference measurement every day at regular intervals, and record the ultrasonic wave propagation time of the reference sample.
And (3) recording data, wherein the measured result is compared with the known thickness, and the data of each calibration are recorded.
2) Automatic correction of sound velocity
Sound velocity calculation:
Where V calibrate is the calibrated speed of sound, d standard is the known standard thickness, and t reflection is the measured reflection time.
And updating the sound velocity, namely updating the calculated sound velocity value into the system parameter so as to be used in subsequent measurement.
3) Parameter drift correction
And correcting signal processing parameters, and adjusting parameters in a signal processing algorithm according to the reference measurement result to ensure that the signal processing algorithm is suitable for environmental changes or equipment aging.
And updating parameters, namely automatically updating signal processing parameters in the system through an algorithm, and keeping the consistency and accuracy of measurement.
2 Fault diagnosis and maintenance
The system is internally provided with a self-diagnosis function and can detect the working states of the transmitter, the receiver and the signal processing unit. When hardware faults are detected, the system can give an alarm in time and give a fault prompt, so that maintenance personnel can conveniently check and replace components.
In the embodiments provided in the present application, it should be understood that the disclosed system and method may be implemented in other manners. For example, the node embodiments described above are merely illustrative, e.g., the division of the modules is merely a logical function division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another device, or some features may be omitted or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be an indirect coupling or communication connection via some interfaces, devices or units, which may be in electrical, mechanical or other form.
The modules described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, may be located in one place, or may be distributed over multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional module in the embodiment of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in hardware plus software functional units.
The foregoing is merely illustrative of embodiments of the present application, and the present application is not limited thereto, and any changes or substitutions can be easily made by those skilled in the art within the technical scope of the present application, and the present application is intended to be covered by the present application. Therefore, the protection scope of the application is subject to the protection scope of the claims.
Claims (9)
1. A sulfur deposit thickness measuring system based on ultrasonic detection, characterized by comprising one or more ultrasonic probes, wherein the ultrasonic probes are respectively arranged at different positions of an oil gas conveying pipeline, and are used for transmitting ultrasonic signals to the oil gas conveying pipeline at a certain frequency and receiving ultrasonic signals reflected back from a sulfur deposit layer of the oil gas conveying pipeline;
the system further comprises a data acquisition and processing device for analyzing the ultrasonic signals and calculating the thickness of the sulfur deposit.
2. The ultrasonic detection-based sulfur deposit thickness measuring system as defined in claim 1, wherein said sulfur deposit thickness measuring system further comprises:
The three-dimensional reconstruction device is used for generating a three-dimensional thickness field (x, y, d) according to sulfur deposition thickness data of a plurality of angles by utilizing an interpolation algorithm and a least square method, wherein x is used for representing a transverse vector of the ultrasonic probe at a spatial position, y is used for representing a longitudinal vector of the ultrasonic probe at the spatial position, and d is used for representing a sulfur deposition thickness vector.
3. A sulfur deposit thickness measurement system based on ultrasonic detection as claimed in claim 1 or 2, wherein said sulfur deposit thickness measurement system further comprises an algorithm correction module, said algorithm correction module further comprising:
The denoising module is used for carrying out frequency domain analysis by adopting wavelet transformation and Fourier transformation and filtering high-frequency noise in the thickness detection result;
And the multi-reflection correction module is used for calculating a correction factor of multi-reflection according to the propagation characteristics of the ultrasonic signals and correcting the thickness of the sulfur deposition layer according to the correction factor.
4. A sulfur deposit thickness measuring system based on ultrasonic detection as defined in claim 3, wherein said sulfur deposit thickness measuring system further comprises:
The automatic data analysis module is used for analyzing the change trend of the sulfur deposition thickness along with time by using a linear regression statistical method according to the detection result stored for a long time;
and the alarm module is used for automatically triggering an alarm function when the detected sulfur deposition thickness value reaches or exceeds a critical thickness value.
5. The ultrasonic detection-based sulfur deposit thickness measuring system as defined in claim 4, wherein said sulfur deposit thickness measuring system further comprises:
The wireless data transmission module is used for transmitting the measurement data to the remote equipment or the cloud;
And the display module is used for displaying the measurement result in real time.
6. A sulfur deposit thickness measuring method based on ultrasonic detection, characterized in that the method is applied to a system having one or more ultrasonic probes respectively installed at different positions of an oil and gas transmission pipe, the method comprising:
a. The ultrasonic probe transmits ultrasonic signals to the oil and gas transmission pipeline at a certain frequency;
b. The ultrasonic probe receives ultrasonic signals reflected back from a sulfur deposition layer of the oil gas conveying pipeline and sends the ultrasonic signals to the data acquisition and processing device;
c. The data acquisition and processing device acquires and utilizes the reflected ultrasonic signals to calculate the thickness of sulfur deposit in the oil and gas pipeline, and the specific calculation method comprises the following steps:
Setting the propagation speed of ultrasonic waves in a sulfur deposition layer as V sulfur, the propagation time as t reflection, and the calculation formula of the thickness d sulfur of sulfur deposition as follows:
Where t reflection is the time delay from transmission to receipt of the reflected signal.
7. The sulfur deposit thickness measuring method based on ultrasonic detection as defined in claim 6, wherein said sulfur deposit thickness measuring method further comprises:
q1. generating a three-dimensional thickness field (x, y, d) by utilizing sulfur deposition thickness data of a plurality of angles and utilizing an interpolation algorithm and a least square method, wherein x is used for representing a transverse vector of an ultrasonic probe at a spatial position, y is used for representing a longitudinal vector of the ultrasonic probe at the spatial position, and d is used for representing a sulfur deposition thickness vector, and specifically comprises the following steps:
using cubic spline interpolation, for a one-dimensional case, the cubic spline interpolation function can be expressed as:
Wherein S i (x) is a spline function for each interval, typically in the form of:
Si(x)＝ai+bi(x-xi)+ci(x-xi)2+di(x-xi)3
By setting the boundary conditions and continuity conditions, the values of a i、bi、ci, and d i can be solved.
The least square method model is as follows:
d(x,y)=A·x
Where d (x, y) is the thickness to be calculated, A is the parameter matrix to be fitted, and x is the vector containing the coordinate information.
The objective of the least squares method is to minimize the following objective function:
The optimal parameter estimation can be obtained by constructing a jacobian matrix J and performing minimization calculation;
for each (x, y) point, the corresponding d value can be calculated through interpolation, and finally, a three-dimensional thickness field (x, y, d) is obtained.
8. A sulfur deposit thickness measuring method based on ultrasonic detection as defined in claim 6 or 7, wherein said sulfur deposit thickness measuring method further comprises:
q2. adopts wavelet transformation and Fourier transformation to carry out frequency domain analysis, and filters high-frequency noise in the thickness detection result.
9. A sulfur deposit thickness measuring method based on ultrasonic detection as defined in claim 6 or 7, wherein said sulfur deposit thickness measuring method further comprises:
q3. calculating a correction factor of the multiple reflections according to the propagation characteristics of the ultrasonic signals, and correcting the thickness of sulfur deposition according to the correction factor;
the correction factor for multiple reflections is calculated, typically based on geometry and media characteristics, expressed as:
where Ri is the influence degree of the ith reflection, and n is the number of reflections.
Then, performing thickness calculation correction, and introducing a correction factor K into a final thickness calculation formula to obtain a corrected thickness d sulfur,corrected as follows:
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