CN113269392B - Method for obtaining corrosion rate of bottom plate of normal-pressure storage tank - Google Patents
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Abstract
The invention relates to the technical field of equipment corrosion monitoring, and particularly discloses a method for acquiring the corrosion rate of a bottom plate of an atmospheric storage tank, which comprises the following steps: linear fitting: performing linear fitting on the L n、CRaen/CR Theory of n of the tank bottom plate sample, and defining the CR aen/CR Theory of n＝Fae cr as an acoustic emission-corrosion rate correction coefficient by F ae cr to obtain a functional formula of F ae cr and L n, namely F ae cr＝f(Ln); obtaining the corrosion rate CR aex of the bottom plate of the storage tank to be detected: and obtaining the corrosion state grade L x of at least one bottom plate of the storage tank to be detected and the theoretical corrosion rate CR Theory of x, obtaining F aex cr based on F ae cr＝f(Ln, and further obtaining CR aex of each bottom plate of the storage tank to be detected according to CR aen/CR Theory of n＝Fae cr. By this method, a relatively accurate acoustic emission-corrosion rate can be obtained.
Description
Technical Field
The invention relates to the technical field of equipment corrosion monitoring, and particularly discloses a method for acquiring a corrosion rate of a bottom plate of an atmospheric storage tank.
Background
Petroleum and petrochemical products are important strategic energy sources in China, so that the national economic development is influenced, and the national safety is related. The storage tank is used as main equipment for petrochemical raw materials and product storage and is widely used in petroleum and petrochemical enterprises. At present, tens of thousands of various types of storage tanks and a plurality of strategic oil storage tank groups are under construction in China, so that the safety and the economy of the oil storage tank are increasingly concerned by the China and enterprises.
The storage tank filled with the oil product runs under the condition of natural environment and liquid level change for a long time, is affected by various adverse factors, inevitably generates various damages, particularly causes the leakage of the stored oil product due to the corrosion perforation of the tank bottom caused by chemical corrosion and electrochemical corrosion in the environment, and causes serious disasters and environmental pollution, thereby causing huge losses to lives and properties of countries and people.
At present, the inspection of the bottom plate of the storage tank in China generally adopts periodic tank opening, and the inspection mainly adopts methods of magnetic flux leakage scanning, ultrasonic thickness measurement, magnetic particle inspection and the like. However, these methods have problems: firstly, for various reasons, many storage tanks cannot be shut down on schedule for conventional tank opening inspection, so that potential safety hazards of different degrees exist; secondly, the detection cost of can opening is high, the detection time is long, and the production is influenced. Therefore, the exploration of a method suitable for online detection of the corrosion rate of the bottom plate of the storage tank is imperative, and has important significance for solving the leakage problem of the bottom plate of the storage tank.
Chinese patent publication CN110333296a relates to a method for calculating the failure probability of a tank bottom plate of an atmospheric storage tank based on acoustic emission detection, which corrects the failure probability of the tank bottom plate directly according to the acoustic emission detection result, thereby correcting the risk, but which does not consider the severity of corrosion thinning of the bottom plate or estimate the corrosion rate according to the acoustic emission detection result, and also does not consider the influence of the number of tests performed in the risk assessment and the validity of the tests on the total damage coefficient D f-total.
In addition, according to national standard GB/T30578-2014 'inspection and evaluation of atmospheric storage tank based on risk' and damage mode identification and corrosion mechanism analysis of a common atmospheric storage tank, the damage mode of the bottom plate is subjected to corrosion thinning, stress corrosion cracking can exist at a local position, and the possibility of brittle fracture is very little, so that the thinning damage factor D thin f-gov is the most important influencing factor of the damage of the bottom plate of the storage tank, and the determination flow is shown in figure 1. It can be seen from fig. 1 that it is critical to measure or estimate the corrosion rate of the base plate, whether the corrosion rate determines reasonably and accurately directly affects the magnitude of the thinning damage factor D thin f-gov. Because of the limitation of the acoustic emission detection technology, the corrosion thinning degree of the bottom plate of the storage tank cannot be measured as the quantitative detection method which can be carried out in the open tank inspection, the corresponding severity index ar/t of the corrosion thinning cannot be given, and the corrosion rate can only be evaluated to participate in the determination flow of the total damage coefficient D f-gov of the bottom plate.
It is worth mentioning that the time interval for the inspection of the inside of the tank in accordance with the medium petroleum industry standard SY/T6620-2014 inspection, repair, rebuilding and rebuilding of tanks is mainly related to the corrosion rate of the tank bottom plate: "6.4.1.2 if selected for inspection during tank operation, sufficient data and information should be collected to evaluate wall thickness, corrosion rate and tank bottom integrity and determine the internal inspection interval based on tank bottom thickness, corrosion rate and tank bottom integrity using the methods described by this standard. The criteria also provide that the corrosion rate of the tank floor is also taken into account when determining the internal test interval by a risk-based test (RBI) program: "6.4.2.4.1 all possible factors that should be considered in RBI evaluation include, but are not limited to: b) Analytical methods for determining the product surface, soil surface and external corrosion rate of the tank wall and tank bottom, and their accuracy; i) Due to the effect of the storage on the internal corrosion rate. So, according to standard requirements, a test is performed during operation of the tank, and a relatively accurate assessment of the corrosion rate of the floor should be made.
In summary, all the existing standards currently require evaluation or assessment of the corrosion rate of the base plate to determine the maintenance cycle of the storage tank, but there is no specific method for assessing the corrosion rate.
Disclosure of Invention
The present invention aims to solve, at least to some extent, the above-described technical problems in the related art. Therefore, the invention provides a method for obtaining the corrosion rate of the bottom plate of the normal pressure storage tank, and solves at least one technical problem.
In order to achieve the above object, the present invention provides a method for obtaining corrosion rate of a bottom plate of an atmospheric storage tank, comprising the steps of:
and (3) data acquisition: acquiring corrosion state grade L 1、L2、L3、L4……Ln of a storage tank bottom plate sample with the numbers of 1,2,3 and 4 … … n through acoustic emission on-line detection, wherein the value range of L 1、L2、L3、L4……Ln is I-V;
obtaining a theoretical corrosion rate CR Theory of 1、CR Theory of 2、CR Theory of 3、CR Theory of 4……CR Theory of n of the storage tank bottom plate sample;
Calculating the maximum measured corrosion rate CR ae1、CRae2、CRae3、CRae4……CRaen of the storage tank bottom plate sample through open tank maintenance;
Linear fitting: performing linear fitting on the L n、CRaen/CR Theory of n of the tank bottom plate sample, and defining the CR aen/CR Theory of n＝Fae cr as an acoustic emission-corrosion rate correction coefficient by F ae cr to obtain a functional formula of F ae cr and L n, namely F ae cr＝f(Ln);
Obtaining the corrosion rate CR aex of the bottom plate of the storage tank to be detected: and obtaining the corrosion state grade L x of at least one bottom plate of the storage tank to be detected and the theoretical corrosion rate CR Theory of x, obtaining F aex cr based on F ae cr＝f(Ln, and further obtaining CR aex of each bottom plate of the storage tank to be detected according to CR aen/CR Theory of n＝Fae cr.
In addition, the method for obtaining the corrosion rate of the bottom plate of the normal pressure storage tank can also have the following additional technical characteristics:
According to some embodiments of the invention, the method further comprises the steps of:
Performing linear fitting on the L n、CRaen/CR Theory of n of the storage tank bottom plate sample and the L x、CRaex/CR Theory of x of the storage tank bottom plate to be detected to obtain a modified F ae cr and L n function formula so as to obtain the corrosion rate of the next storage tank bottom plate or the next batch of storage tank bottom plates;
And so on, repeated several times.
According to some embodiments of the invention, a linear fit is performed with L n on the abscissa and CR aen/CR Theory of n on the ordinate.
According to some embodiments of the invention, the theoretical corrosion rate of the tank bottom plate sample or the tank bottom plate to be tested is obtained by analyzing the damage mode and the corrosion mechanism of the tank bottom plate sample or the tank bottom plate to be tested.
According to some embodiments of the invention, the CR aex deviates from CR Theory of x by less than 10%.
According to some embodiments of the invention, the absolute value of the deviation of F ae cr from F x cr is less than 5%.
According to some embodiments of the invention, the linear fit comprises a straight line fit or a curve fit.
According to some embodiments of the invention, the atmospheric storage tank is a crude oil storage tank.
According to some embodiments of the invention, the volume V of the atmospheric tank satisfies the relationship: v is more than or equal to 5 ten thousand cubic meters and less than or equal to 10 ten thousand cubic meters.
According to some embodiments of the invention, the method further comprises the steps of:
The remaining life of the tank floor, the service cycle, the damage coefficient D f-total, the thinning damage factor D thin f-gov and the severity index ar/t of the corrosion thinning are calculated from CR aex.
Compared with the prior art, the invention has the following beneficial effects:
The method for acquiring the corrosion rate of the bottom plate of the normal-pressure storage tank can relatively accurately estimate the corrosion rate CR ae of the bottom plate of the storage tank through the acoustic emission-corrosion rate correction coefficient F ae cr according to the corrosion rate of the bottom plate of the storage tank which is counted by the prior theory and experience, and can be used for calculating the residual life of the bottom plate of the storage tank, the maintenance period and the damage coefficient D f-total in risk assessment. And through the continuous implementation of the method, the acoustic emission-corrosion rate correction coefficient F ae cr can be continuously supplemented and perfected, and the acoustic emission-corrosion rate CR ae obtained by the method can be continuously updated and corrected in a self-circulation way, so that the use accuracy of the acoustic emission-corrosion rate CR ae is improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to the structures shown in these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart for determining a thinning damage factor D thin f-gov in the prior art;
FIG. 2 is a plot of L ae and CR ae/CR Theory of scatter plots and a linear fit in example 1 of the present invention;
FIG. 3 is an updated L ae and CR ae/CR Theory of scatter plot and linear fit in example 1 of the present invention.
The achievement of the objects, functional features and advantages of the present invention will be further described with reference to the accompanying drawings, in conjunction with the embodiments.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
Unless defined otherwise, all technical and scientific terms used hereinafter have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the scope of the present invention.
The invention provides a method for obtaining corrosion rate of a bottom plate of an atmospheric storage tank, which can obtain relatively accurate acoustic emission-corrosion rate CR ae, and specifically comprises the following steps:
and (3) data acquisition: acquiring corrosion state grade L 1、L2、L3、L4……Ln of a storage tank bottom plate sample with the numbers of 1,2,3 and 4 … … n through acoustic emission on-line detection, wherein the value range of L 1、L2、L3、L4……Ln is I-V;
obtaining a theoretical corrosion rate CR Theory of 1、CR Theory of 2、CR Theory of 3、CR Theory of 4……CR Theory of n of the storage tank bottom plate sample;
Calculating the maximum measured corrosion rate CR ae1、CRae2、CRae3、CRae4……CRaen of the storage tank bottom plate sample through open tank maintenance;
Linear fitting: performing linear fitting on the L n、CRaen/CR Theory of n of the tank bottom plate sample, and defining the CR aen/CR Theory of n＝Fae cr as an acoustic emission-corrosion rate correction coefficient by F ae cr to obtain a functional formula of F ae cr and L n, namely F ae cr＝f(Ln);
Obtaining the corrosion rate CR aex of the bottom plate of the storage tank to be detected: and obtaining the corrosion state grade L x of at least one bottom plate of the storage tank to be detected and the theoretical corrosion rate CR Theory of x, obtaining F aex cr based on F ae cr＝f(Ln, and further obtaining CR aex of each bottom plate of the storage tank to be detected according to CR aen/CR Theory of n＝Fae cr.
And calculating the residual service life, the maintenance period, the damage coefficient D f-total, the thinning damage factor D thin f-gov and the severity index ar/t of corrosion thinning of the bottom plate of the storage tank to be detected according to the CR aex.
Performing linear fitting on the L n、CRaen/CR Theory of n of the storage tank bottom plate sample and the L x、CRaex/CR Theory of x of the storage tank bottom plate to be detected to obtain a modified F ae cr and L n function formula so as to obtain the corrosion rate of the next storage tank bottom plate or the next batch of storage tank bottom plates;
And so on, repeated several times.
Next, the present invention will be described in detail with reference to the following application examples:
example 1
Some crude oil reservoir 510 ten thousand cubic meter crude oil storage tanks. The material of the bottom plate edge plate is 12MnNiV or SPV490Q, and the thickness is 20mm; the middle web material is Q235-B, and the thickness is 11mm. The tank bottom is provided with an inner coating and is liner-free, the upper surface of the tank bottom is provided with a sacrificial anode block, the lower surface is externally connected with forced current cathodic protection, the tank foundation is continuous asphalt concrete, and the settlement detection and the type of the bottom plate meet the standard requirements. RBI was performed on the reservoir area in 2016-2018, on-line inspection, risk assessment, can opening and maintenance were performed, and statistics on the bottom plate detection and evaluation results are shown in Table 1:
TABLE 1 statistics of RBI results for 5 tank floors in a warehouse area
Because the 5 cans are designed, built and accepted according to the same standard, the service conditions are substantially the same, and therefore the theoretical corrosion rates CR Theory of are the same. However, due to unavoidable differences in construction quality, operation maintenance, crude oil quality storage and the like, differences exist between on-line inspection and can opening inspection results before and after the first overhaul period. The quotient of the measured corrosion rate and the theoretical corrosion rate of the 5 cans was calculated, and the results are shown in Table 2.
TABLE 2 statistics of RBI results for 5 tank floors in a warehouse area
| Storage tank position number | Acoustic emission detection level L ae | CR Actual measurement /CR Theory of |
| T04 | I | 0.39 |
| T06 | I | 0.57 |
| T08 | Ⅱ | 1.49 |
| T41 | Ⅱ | 1.93 |
| T07 | Ⅱ | 2.38 |
Correlation analysis was performed with L ae and CR Actual measurement /CR Theory of and a linear fit was performed as shown in fig. 2.
Since the R 2 value 0.9899 is larger than 0.9, the linear fitting correlation is strong, CR Actual measurement /CR Theory of ＝Fae cr, and the correlation equation is used as a calculation formula of the acoustic emission-corrosion rate correction coefficient F ae cr, the corresponding relation table of the acoustic emission detection corrosion state level L ae and the acoustic emission-corrosion rate correction coefficient F ae cr in the reservoir area is shown in table 3.
TABLE 3 correspondence table between corrosion status level L ae and correction coefficient F ae cr
In the reservoir 2020, two crude oil tanks of the same specification are subjected to tank opening rechecking, and compared with the acoustic emission-corrosion rates CR ae corrected according to Table 3 in the acoustic emission detection results of tank bottom plates in 2018 and 2019, and the results are shown in Table 4.
TABLE 4 statistics of RBI results for 2 additional tank floors in a warehouse area
Note that: correction deviation= (CR ae-CR Actual measurement )/CR Actual measurement ×100%.
As can be seen from Table 4, after the acoustic emission-corrosion rate correction coefficient F ae cr obtained by the method is applied to other storage tanks in the reservoir area, the deviation between the corrected result and the actual detection result is less than 10%, so that the engineering detection requirement is met. The data of table 4 was added to table 1, and the correction and update of F ae cr were performed, and the results are shown in fig. 3.
Since R 2 value is greater than 0.9995 and the correlation equation is used as the updated calculation formula of the acoustic emission-corrosion rate correction coefficient F ae cr, the table of the correspondence between the acoustic emission detection corrosion state grade L ae of the reservoir area and the acoustic emission-corrosion rate correction coefficient F ae cr is shown in Table 5.
TABLE 5 first update of the correspondence table between corrosion status level L ae and correction coefficient F ae cr
Note that: the ratio of the first updated to first determined difference F ae cr to first determined F ae cr is taken as the bias.
As can be seen from fig. 3, the value of the correlation coefficient R 2 of the linear fitting after supplementing the new data is improved, the variation range of the acoustic emission-corrosion rate correction coefficient F ae cr is smaller, and the absolute value of the deviation before and after updating is smaller than 2%, so that the method is feasible and effective.
Example 2
A wharf tank area is provided with 15 ten thousand cubic meters of crude oil storage tanks, and the operation is put into production in 9 months of 1994. The material of the bottom plate edge plate is 16MnR, and the thickness is 12mm; the middle web material is A 3 F, and the thickness is 8mm. The tank bottom is provided with an inner coating and no lining, the cathode protection is arranged at the tank bottom, and the tank foundation is continuous asphalt concrete. And (3) carrying out damage mode and corrosion mechanism analysis on the tank, wherein the main damage mode of the tank bottom plate is corrosion thinning, the corrosion rates of the bottom plate on the product side and the soil side are CR P＝0.1397mm/a,CRS = 0.0692mm/a respectively, the corrosion type is local corrosion, and the product side with a larger corrosion rate is used as the corrosion rate of the bottom plate. And (4) carrying out acoustic emission detection once in 2006, and evaluating the corrosion state grade of the bottom plate of the storage tank as grade IV. Since the wharf reservoir was not subjected to large-scale RBI technology application, but the use and conditions of the cans were similar to those of the cans of example 1, the corrosion rate of the bottom plate of the cans was estimated with reference to the correspondence between the corrosion state levels L ae and the correction coefficients F ae cr of table 5, and the acoustic emission-corrosion rate CR ae = 0.4945mm/a. This jar 2016 years emergence seepage accident overhauls through clear jar, discovers that bottom plate many places are local to corrode, and the most serious department of magnetic leakage detectable position is marginal board corrosion equivalent 80%, and the medium plate detects and discovers the corruption perforation, actual measurement corrosion rate: edge plate 0.4364mm/a, middle plate 0.3636mm/a, and maximum measured corrosion rate of the bottom plate 0.4364mm/a. The accuracy of the acoustic emission-corrosion rate CR ae calculated as in example 1 was 86.7%.
From this, it is clear that the accuracy of the estimation of the acoustic emission-corrosion rate CR ae by the use of the correction coefficient of the reservoir region with similar conditions for the smaller scale tank region is 85% or more. The invention has certain universality under the condition that the materials, the running conditions and the service conditions of the storage tank are similar.
The present invention is not limited to the above-mentioned embodiments, and any changes or substitutions that can be easily understood by those skilled in the art within the technical scope of the present invention are intended to be included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (5)
1. A method of obtaining an atmospheric storage tank floor corrosion rate comprising the steps of:
and (3) data acquisition: acquiring corrosion state grade L 1、L2、L3、L4……Ln of a storage tank bottom plate sample with the numbers of 1,2,3 and 4 … … n through acoustic emission on-line detection, wherein the value range of L 1、L2、L3、L4……Ln is I-V;
obtaining a theoretical corrosion rate CR Theory of 1、CR Theory of 2、CR Theory of 3、CR Theory of 4……CR Theory of n of the storage tank bottom plate sample;
Calculating the maximum measured corrosion rate CR ae1、CRae2、CRae3、CRae4……CRaen of the storage tank bottom plate sample through open tank maintenance;
Linear fitting: a linear fit was performed on L n、CRaen/CR Theory of n of the tank floor sample,
CR aen/CR Theory of n＝Fae cr, wherein F ae cr is defined as an acoustic emission-corrosion rate correction coefficient, and a functional formula of F ae cr and L n, namely F ae cr＝f(Ln is obtained;
obtaining the corrosion rate CR aex of the bottom plate of the storage tank to be detected: acquiring the corrosion state grade L x of at least one bottom plate of the storage tank to be detected and the theoretical corrosion rate CR Theory of x, obtaining F aex cr based on F ae cr＝f(Ln, and further obtaining CR aex of each bottom plate of the storage tank to be detected according to CR aen/CR Theory of n＝Fae cr;
The method also comprises the following steps:
Performing linear fitting on the L n、CRaen/CR Theory of n of the storage tank bottom plate sample and the L x、CRaex/CR Theory of x of the storage tank bottom plate to be detected to obtain a modified F ae cr and L n function formula so as to obtain the corrosion rate of the next storage tank bottom plate or the next batch of storage tank bottom plates;
Repeating the steps for a plurality of times by analogy;
performing linear fitting by taking L n as an abscissa and CR aen/CR Theory of n as an ordinate;
Obtaining a theoretical corrosion rate of the storage tank bottom plate sample or the storage tank bottom plate to be detected by analyzing a damage mode and a corrosion mechanism of the storage tank bottom plate sample or the storage tank bottom plate to be detected;
The deviation of the CR aex from the CR Theory of x is less than 10%;
The absolute value of the deviation of F ae cr from F x cr is smaller than 5%.
2. The method of deriving an atmospheric tank floor corrosion rate according to claim 1, wherein said linear fit comprises a straight line fit or a curve fit.
3. The method of deriving corrosion rates for a base plate of an atmospheric storage tank according to claim 1, wherein said atmospheric storage tank is a crude oil storage tank.
4. The method of deriving an atmospheric tank floor corrosion rate according to claim 1, wherein the volume V of the atmospheric tank satisfies the relationship: v is more than or equal to 5 ten thousand cubic meters and less than or equal to 10 ten thousand cubic meters.
5. The method of deriving an atmospheric tank floor corrosion rate according to any one of claims 1-4, further comprising the step of:
The remaining life of the tank floor, the service cycle, the damage coefficient D f-total, the thinning damage factor D thin f-gov and the severity index ar/t of the corrosion thinning are calculated from CR aex.
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| CN113269392B true CN113269392B (en) | 2024-04-19 |
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