黄土塬区原油集输管道腐蚀检测及剩余寿命预测

为了识别壁厚减薄原因,掌握管道运行状态,以XFZ转油站至WTL联合站埋地集输管道为研究对象,绘制腐蚀开挖检测专题图,开展腐蚀产物特性、边缘腐蚀状态试验研究,预测管道剩余寿命。结果表明:目标管道以内腐蚀为主,腐蚀点沿内壁随机分布,腐蚀速度级别为"重",腐蚀程度级别为"严重";腐蚀类型为Cl+O_2+CO_2+H_2O环境下的垢下腐蚀,以溶解氧、CO_2腐蚀为主,Cl~-腐蚀为辅;腐蚀原因为介质含水率较高,流速偏低,水中含有溶解氧和CO_2,且Cl~-含量过高;目标管道最大剩余寿命为3.52年,平均剩余寿命为2~3年,F管段已达到剩余寿命极限需立即更换。     

石脑油输送管道腐蚀减薄分析

某石化公司一条石脑油输送管道某弯头部位在停车检验时发现局部存在严重减薄,经切割后发现内壁腐蚀严重并存在多处腐蚀坑。本文拟通过宏观形貌分析、金相组织分析、腐蚀产物微观分析以及腐蚀产物XRD分析等方法对其腐蚀减薄原因进行研究。结果表明,由于输送介质中含有硫、氯等腐蚀性离子,在服役过程中管道内壁发生腐蚀形成腐蚀层,由于局部闭塞效应,诱发小的点蚀坑,导致腐蚀层疏松,发生不定期的剥落,造成管道不断减薄;而在腐蚀产物堆积垢层下由于闭塞效应而发生垢下腐蚀,形成局部的坑状腐蚀。     

石化防腐 预防为主 “治疗”为辅——访中国石油石化防腐蚀新技术开发中心技术总监宋广成

<正>据《中国工业与自然环境腐蚀问题调查与对策》统计数据,石油化工行业的腐蚀损失占其总产值的6%左右,高于其他行业的1倍以上。随我国石油化工行业的迅猛发展,原油劣质化、设备腐蚀严重等因素造成的安全形势也愈发严峻。青岛"11·22"中石化东黄输油管道泄漏爆炸特别重大事故,其初始原因正是:输油管道与排水暗渠交汇处管道腐蚀减薄、管道破裂、原油泄漏。为探讨石油化工行业腐蚀技术的发展趋势、具体应用,有效预防     

基于改进PSO-BPNN的输油管道内腐蚀速率研究

为解决输油管道易腐蚀,且腐蚀程度难以测量的问题,提出使用改进的粒子群算法（PSO）优化误差反向传播神经网络（BPNN）对输油管道内腐蚀速率进行预测。改进的PSO算法提升了自身搜索到全局最优的能力,可为BPNN提供最优初始权值和阈值,从而有效避免BPNN易陷入局部最优的问题发生。以某条输油管线为例,分别运用标准的BPNN模型、PSO-BPNN以及改进的PSO-BPNN对该管线内腐蚀速率进行预测。结果表明:基于改进的PSO-BPNN的预测结果平均相对误差为5.57%,预测精度较BPNN和PSO-BPNN有明显提升。使用改进的PSO-BPNN预测输油管道的腐蚀速率可为管道的检测维修提供可靠的理论和技术支撑。     

工程建设中的源头安全问题思考

2013年＂11·22＂中石化东黄输油管道泄漏爆炸特别重大事故,造成62人死亡、136人受伤,直接经济损失7.5亿元。经调查认定,事故发生的直接原因是输油管道与排水暗渠交汇处管道腐蚀减薄、管道破裂、原油泄漏,流入排水暗渠及反冲到路面。原油泄漏后,现场处置人员采用液压破碎锤在暗渠盖板上打孔破碎,产生撞击火花,引发暗渠内油气爆炸。     

计量分离器至加热炉生产汇管腐蚀失效分析

计量分离器至加热炉的生产汇管,由于其输送介质的特殊性,汇管出现腐蚀失效。通过对腐蚀失效油管进行的化学成分分析、金相分析、腐蚀区域微观分析和油腐蚀产物评价,结果表明失效与材质无关,其化学成分均符合技术协议要求并由铁素体+珠光体组成。腐蚀介质中由于含有溶解氧,钢材表面发生了氧还原反应,钢材表面形成酥松的α-FeOOH,并由于氯离子的存在,最终导致生产汇管由内腐蚀发展为腐蚀穿孔。     

基于ASME B31G准则的油气管道腐蚀安全性评估

腐蚀是在役管道失效的最主要原因之一。腐蚀后的管道会造成局部减薄,使其局部承载力下降,一旦发生泄漏,极易发生火灾爆炸事故。采用通用的ASME B31G准则对管道进行腐蚀安全性评估,研究了不同级别管道的最大允许缺陷长度和最大安全运行压力,计算了不同腐蚀长度对管道安全性的影响,可以为管道维护策略和应急管理提供科学依据。     

普光高含硫气田集输管道冲蚀规律及预测模型研究

基于灰色关联分析方法,根据集输管道在线腐蚀监测数据,采用剪切应力表征湍流两相流动对管道内壁的冲刷作用,以湍流强度表征湍流传质强化对腐蚀的影响程度,同时集成普光气田集输管道室内静态腐蚀实验数据,建立了普光气田集输管道动态腐蚀预测模型,为普光气田集输系统腐蚀监测及安全管理提供了依据。     

电站锅炉水冷壁管腐蚀失效分析

为探究电厂水冷壁爆管事故的成因,本文对失效水冷壁管进行了宏观分析与理化分析,采用X射线衍射仪(XRD)、光学显微镜(OM)、扫描电子显微镜(SEM)和能谱仪(EDS)对腐蚀产物的晶体结构、腐蚀部位显微组织进行了细致分析,在此基础上对水冷壁管的腐蚀机理进行了推断,得出了该水冷壁管失效的原因是水冷壁内壁发生了局部氧腐蚀,水中的氯离子作为催化剂加快了氧腐蚀速度。     

天然气管道内腐蚀影响因素的灰色综合关联度分析

对天然气管道内腐蚀的评价是管道腐蚀与防护工作中的重要环节。为对天然气管道内腐蚀进行风险分析,引入了系统理论中灰色综合关联度的相关知识。采用该方法,以H2S、CO2和缓蚀剂3项造成天然气管道内腐蚀的因素为例,列出了灰色关联度分析的具体步骤,并对各因素进行灰色综合关联度计算。结果表明,该方法的评价结果与期望值相符,可以作为评价天然气管道内腐蚀的一种新方法。     

工业锅炉烟管氯离子腐蚀原因分析

某DZL(SG)-1.25-M、Q-Ⅱ型工业锅炉的烟管水侧出现大量腐蚀凹坑,腐蚀烟管更换后不足一个月,烟管再次出现明显的腐蚀倾向.试验分析表明:水处理交换树脂清洗不彻底引起给水氯离子偏高,排污不足导致锅水中的氯离子和溶解固形物进一步浓缩,溶解固形物高于标准GB/T 1576-2018要求,受热烟管水侧外壁最终在锅水高浓度氯离子作用下发生了电化学腐蚀.     

Internal corrosion hazard assessment of oil & gas pipelines using Bayesian belief network model

A substantial amount of oil & gas products are transported and distributed via pipelines, which can stretch for thousands of kilometers. In British Columbia (BC), Canada, alone there are over 40,000 km of pipelines currently being operated. Because of the adverse environmental impact, public outrage and significant financial losses, the integrity of the pipelines is essential. More than 37 pipe failures per year occur in BC causing liquid spills and gas releases, damaging both property and environment. BC oil & gas commission (BCOGS) has indicated metal loss due to internal corrosion as one of the primary causes of these failures. Therefore, it is of a paramount importance to timely identify pipelines subjected to severe internal corrosion in order to improve corrosion mitigation and pipeline maintenance strategies, thus minimizing the likelihood of failure. To accomplish this task, this paper presents a Bayesian belief network (BBN)-based probabilistic internal corrosion hazard assessment approach for oil & gas pipelines. A cause-effect BBN model has been developed by considering various information, such as analytical corrosion models, expert knowledge and published literature. Multiple corrosion models and failure pressure models have been incorporated into a single flexible network to estimate corrosion defects and associated probability of failure (PoF). This paper also explores the influence of fluid composition and operating conditions on the corrosion rate and PoF. To demonstrate the application of the BBN model, a case study of the Northeastern BC oil & gas pipeline infrastructure is presented. Based on the pipeline's mechanical characteristics and operating conditions, spatial and probabilistic distributions of corrosion defect and PoF have been obtained and visualized with the aid of the Geographic Information System (GIS). The developed BBN model can identify vulnerable pipeline sections and rank them accordingly to enhance the informed decision-making process.     

埋地油气管道沿线土壤腐蚀性可拓评价研究

油气管道长期埋设在土壤环境中会受到各种侵蚀介质的腐蚀并引发泄漏、火灾、爆炸等事故。针对土壤腐蚀因素复杂多变的特点,建立基于物元、可拓集合和关联函数的埋地油气管道沿线土壤腐蚀性评价模型;选取土壤电阻率、自然电位、氧化还原电位、pH值、含水率、Cl-含量、SO42-含量7个评价指标,将土壤对油气管道腐蚀的严重程度划分为低、较低、中、强和较强5个等级;采用客观赋权的变异系数法（CV法）来确定土壤腐蚀性评价指标的权重,避免了以往评价方法的主观性,进一步提高模型的精度和效率。以某埋地天然气管道5个管段土壤为例,可拓评价结果表明4#土壤的腐蚀性较强,其他土壤腐蚀性中等,这与外腐蚀检测结果吻合,证明所想出的模型简便、高效、精确,具有很好的科学性和工程应用性。     

基于TVR的腐蚀油气管道失效概率及安全寿命研究

为避免因腐蚀导致油气管道失效，针对因管道特性和腐蚀尺寸的不确定性使得管道剩余强度成为概率模型的特点，建立了腐蚀管道强度损失随机模型；借助可靠性理论，通过分析管道腐蚀进程的时变性特点，将管道系统由损伤积累和抗力衰减导致的剩余强度随机化；提出基于穿越率的腐蚀油气管道失效评定及安全寿命预测方法。研究结果表明:腐蚀速率和运行压力对管道失效概率及安全寿命影响显著,管道尺寸影响适中，而相关系数和拉伸强度影响较小；若腐蚀速率Va=0.2 mm/a，VL=10 mm/a或局部腐蚀缺陷半径达到管道壁厚的0.5倍时，建议作为重点风险段监测并检修。所建方法是对腐蚀油气管道运营监控和风险评估的有益补充。     

换热器不锈钢换热管束开裂原因分析

一台换热器换热管束发生了开裂泄漏.采取全面检验的方式,通过宏观检查、化学成分分析、断口微观形貌和能谱分析、金相分析等方法,对换热管开裂原因进行了分析.结果表明:该换热管开裂为氯化物应力腐蚀开裂.壳程介质循环冷却水中CI元素含量是应力腐蚀开裂的主要因素,结构缺陷、敏感的工作温度区间、水中溶解氧和含S杂质导致了应力腐蚀的快速发展.     

Experimental studies of crevice corrosion for buried pipeline with disbonded coatings under cathodic protection

Numerous fire and explosion accidents have occurred because of pipeline ruptures through the corrosion area. Coatings under cathodic protection (CP) have been recognized to prevent/mitigate potential pipeline corrosion. In this work, a wedge-shaped crevice assembly was developed to study the effect of cathodic protection on corrosion of 20# steel pipeline with disbanded coatings. Polarization potential, current density, solution pH value, and dissolved oxygen concentration were measured by using the simulation of crevice area with disbonded coatings. Results have demonstrated that CP cannot reach the crevice bottom which reduces the effectiveness of corrosion protection. This effectiveness depends on the crevice geometry and could be improved with the increase of crevice length and decrease of its mouth size. A potential difference always exists between the mouth area and inside crevice. The oxygen concentrations drop significantly inside crevice whether CP is applied or not. The solution pH values inside crevice increase with the time. The solution pH values are higher when the applied CP potentials are more negative. According to the experiments, the effectiveness of cathodic protection could also be improved through enhancement of the local solution alkalinity. The research provides necessary information to prevent potential pipeline ruptures due to crevice corrosion and therefore mitigate potential losses for oil and gas transportation in the process industries.     

保温层下管道腐蚀监测系统及应用研究

为预防保温层下管道腐蚀带来的严重问题,必须采取有效措施进行腐蚀在线监测,以了解管道的剩余壁厚情况。在分析现有的腐蚀监测技术不足的前提下,基于γ射线数字扫描检测技术（GSDT）,研发了1套保温层下管道腐蚀在线监测系统,该系统可以实现对保温层下腐蚀管道剩余壁厚在线监测,并通过带保温层管道的检测试验和t-分布分析方法检验腐蚀监测系统的检测精度,最后以某化工企业为例,验证了该系统的有效性。结果表明:腐蚀监测系统可以实现对保温层管道剩余壁厚的监测,保温层和高密度介质不影响管壁厚度的测量结果,且使用所研发的腐蚀监测系统监测到的管道腐蚀速率与现场实际腐蚀速率基本一致。     

红—克长输玻璃管线沿程压力和温度分布影响因素分析

为确定红—克长输玻璃管线常温输送方案,根据现场管线工况,利用Pipephase 软件建立了管道数值仿真模型,分析了原油含水率、输送流量、管道内壁粗糙度、环境 温度、入口温度等因素对管线沿程压力和温度分布的影响规律。结果表明:原油含水率 、输送流量、管壁粗糙度的增加会导致管线沿程压降增大;环境温度、入口温度的增加 会造成管线沿程压降减小,且压降变化趋势基本一致;原油含水率、入口温度的增加, 会引起管线沿程温降的增大;输送流量、环境温度的增加,会造成管线沿程温降的减小 ;管壁粗糙度对管线沿程温降影响较小。该研究工作为玻璃钢管线长输方案的制定提供 了参考依据,对保障油气安全运输具有重要的工程意义。     

A mathematical model of crevice corrosion for buried pipeline with disbonded coatings under cathodic protection

Crevice corrosion occurs in a holiday and disbonded region between coating and pipeline steel. Cathodic protection (CP) is generally recognized as the most effective method for corrosion prevention of pipeline, but its effectiveness may be reduced at defects in a disbonded coating. It is difficult to measure and probe corrosion parameters accurately based on experimental work. Therefore, a mathematical model is necessary to identify the phenomena and mechanisms that contribute to the crevice corrosion process. In this work, a mathematical model was developed to determine the evolution of chemical and electrochemical transient processes of crevice corrosion in NaCl dilute solution, and the effect of cathodic protection and crevice width on corrosion of 20# steel pipeline with disbonded coatings. Results have demonstrated that the extent of crevice corrosion depends on the crevice geometry and could be influenced by the increase of crevice depth and decrease of its width. The oxygen concentrations drop significantly inside a crevice whether CP is applied or not and whether crevice width decreased or not. The pH values and conductivity of crevice solution increase with the time. The research provides a theoretical foundation for cathodic protection of pipelines and establishes an effective corrosion model which can identify the phenomena and mechanisms of the crevice corrosion process. This work could be used to help mitigate the corrosion failure of pipelines to prevent catastrophic accidents in oil, gas and chemical process industries.