The chemical industry is a fundamental and pillar industry of the national economy, penetrating into many fields such as energy, materials, medicine, electronics, etc. Its stable operation is directly related to the security of the industrial and supply chains and the overall economic and social development. In chemical production, most chemical raw materials and finished products have strong corrosiveness, and the system is often under high temperature (some devices reach above 300 ℃) and high pressure conditions. In addition, the erosion and wear caused by medium flow, stress corrosion caused by temperature fluctuations, etc., can lead to continuous thinning of the inner wall of the pipeline. Once the wall thickness exceeds the safety threshold, it may cause medium leakage, not only causing equipment shutdown, but also posing a threat to personnel safety and the surrounding environment due to chemical diffusion. Therefore, accurate and efficient wall thickness detection has become the core link of equipment maintenance in chemical enterprises.

Pain points of traditional detection technology: why is it difficult to cope with chemical scenarios?

Traditional thickness measurement techniques such as piezoelectric ultrasonic waves often face various challenges in the chemical industry

1. High temperature environmental limitations: Some equipment pipelines have temperatures exceeding 200 ℃, and traditional coupling agents quickly evaporate at high temperatures, resulting in acoustic impedance mismatch and significant measurement errors;

2. Surface treatment challenge: The anti-corrosion coating and oxide layer on the outer wall of the pipeline need to be removed before detection, which not only increases the workload but may also damage the anti-corrosion layer and exacerbate corrosion;

3. Limitations of offline detection: Relying on manual recording of corrosion data and input to form detection records, the data lags behind and is difficult to effectively manage and utilize, making it impossible to form continuous corrosion trend analysis.

Digital manual inspection+online corrosion monitoring, building a digital protection network

1. Pen type electromagnetic ultrasonic thickness gauge: a portable and efficient on-site inspection tool

1) Non contact detection: No coupling agent required, can directly penetrate 3-5mm anti-corrosion coating or insulation layer, suitable for complex states such as slight corrosion and roughness on pipeline surfaces;

2) High temperature adaptability: It has good high temperature resistance and high precision characteristics, and is dynamically corrected by temperature sensors to ensureData stability.

3) Easy to operate: The pen style design is suitable for detecting small spaces, allowing for one click data acquisition and storage of thickness measurement data on the platform.

2. Corrosion online monitoring system: real-time protection of critical pipelines

1) 24-hour continuous monitoring: suitable for installation and deployment in major high-risk areas such as elbows and valves, real-time collection of wall thickness data;

2) Digital management platform: Synchronize data to the management platform, generate corrosion rate curves, and set threshold warnings;

3) Historical tracing and analysis: Monitoring data supports exporting and comparing, providing scientific basis for maintenance plans.

Case Background

Part of the raw material and product transportation pipelines of a large chemical enterprise operate in an environment of 200 ℃ -320 ℃ for a long time. Due to corrosion and erosion of the medium, there is a risk of corrosion and thinning of the pipeline, which can easily lead to unplanned parking. Originally adoptedpiezoelectric ultrasoundTesting requires regular shutdown to remove insulation layers and coatings, which not only has a long testing cycle and low efficiency, but also results in large data deviations in high-temperature environments, making it difficult to accurately locate risk points. To meet higher safety production requirements, the company contacted us through relevant channels and introduced an intelligent pipeline corrosion monitoring system to achieve precise detection and improve efficiency without affecting production.

inspection site

After understanding the working conditions and the needs of the owner on site, Changchuan ultrasonic technicians identified pipeline connections such as elbows, tees, and valves as key monitoring locations. These areas are prone to corrosion and thinning due to factors such as fluid erosion, sedimentation, or pressure stress concentration. In response to on-site inspection requirements, Changchuan Ultrasonic has developed a corrosion data collection and risk prevention plan that combines digital inspection and online corrosion monitoring.

According to the corresponding technical plan, on-site technicians use quick release straps and bases to fix digital manual inspection labels and electromagnetic ultrasonic nodes on the tested workpiece.