Corrosion proxy material integrated sensor devices for distributed sensing of early corrosion onset and corrosion quantification
Inventors
Ohodnicki, JR., Paul R. • Ziomek-Moroz, Malgorzata
Assignees
Publication Number
US-11262289-B1
Publication Date
2022-03-01
Expiration Date
2036-12-30
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Abstract
Embodiments relate to methods, systems and apparatus for detecting corrosion using a detector apparatus with a host component. The method includes a detector apparatus. The detector apparatus includes an energy source; a corrosion proxy thin film that corrodes at a rate where the normalized change of mass of the film over time is greater than the normalized change of mass of the bulk material of the host component in a harsh environment; and the detector, wherein the detector is capable of detecting a change in energy due to corrosion of the corrosion proxy thin film. The method includes exposing the host component and the corrosion proxy thin film to the harsh environment; and detecting a change in energy using the detector due to corrosion of the corrosion proxy thin film.
Core Innovation
The invention relates to methods, systems, and apparatus for detecting corrosion using a detector apparatus integrated with a host component. The key innovation involves utilizing a corrosion proxy thin film that corrodes at a rate where the normalized change of mass over time is greater than that of the bulk material of the host component when exposed to a harsh environment. This corrosion proxy thin film is integrated with a detector capable of detecting changes in energy due to the corrosion of the proxy film, allowing early detection and quantification of corrosion onset.
The background identifies significant challenges in monitoring corrosion in harsh subsurface environments such as natural gas pipelines, oil and gas wellbores, and offshore underwater reserves. These environments have extreme temperature and pressure conditions and chemically corrosive species that complicate sensor deployment. Conventional electrical sensors suffer instability and failure under such conditions, especially due to the need for electrical connections at the sensing location. The problem solved is the lack of suitable sensors that can operate reliably in these harsh environments and enable distributed, wireless, and wide-area corrosion monitoring.
The invention solves this problem by integrating corrosion proxy materials with advanced sensor platforms such as optical fibers and surface acoustic wave devices. These platforms enable wireless, distributed monitoring with low cost and sensitivity to changes in optical, electrical, strain/stress, or mass properties caused by corrosion reactions in the proxy materials. The corrosion proxy materials can be engineered or selected to reflect early corrosion onset conditions relevant to the bulk infrastructure, providing proactive warning and quantification capabilities that overcome shortcomings of conventional electrochemical sensors requiring direct electrical contacts.
Claims Coverage
The patent includes two independent claims covering methods and apparatus for corrosion detection integrating corrosion proxy thin films with optical sensing systems.
Method for detecting corrosion using an optical corrosion proxy thin film
A method employing a detector apparatus comprising a light source, a corrosion proxy thin film that corrodes at a rate faster than the host bulk material under harsh conditions, and an optical detector capable of detecting changes in light transmission through an optical fiber due to corrosion of the proxy thin film. The method includes exposing the host component and proxy thin film to the harsh environment and detecting changes in energy corresponding to corrosion onset.
Detector apparatus with corrosion proxy thin film embedded in an optical system
An apparatus comprising a light source, a corrosion proxy thin film composed of at least one metal embedded in an oxide that corrodes faster than the host bulk material, an optical detector capable of detecting changes in energy from corrosion of the proxy film, and an optical fiber communicating the light source, proxy film, and detector, enabling detection of light changes through the fiber due to corrosion.
The claims cover systems and methods integrating a corrosion proxy thin film corroding faster than the host material with optical interrogation means, specifically involving optical fibers and optical backscattering detection, for early detection of corrosion onset via changes in energy or light transmission.
Stated Advantages
Ability to measure early corrosion onset using corrosion proxy materials integrated with advanced sensor platforms.
Capability for multi-parameter functionality including temperature and strain sensing in addition to corrosion monitoring.
Use of corrosion proxy materials comprising thin films related to the bulk infrastructure material, sacrificial or corrosion resistant layers, or materials sensitive to particular corrosive species.
Enables distributed and wireless monitoring through optical or microwave telemetry and interrogation techniques.
Provides corrosion rate monitoring through exploitation of various corrosion proxy materials.
Documented Applications
Corrosion monitoring in natural gas pipelines.
Monitoring in electricity transmission and distribution networks.
Wells and wellbore corrosion monitoring.
Corrosion monitoring in water pipelines.
Monitoring corrosion in bridges and buildings.
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