Distributed fiber-optic sensor network for sensing the corrosion onset and quantification
Inventors
Ohodnicki, Jr., Paul R • Lu, Ping • Wright, Ruishu • Devkota, Jagannath
Assignees
Publication Number
US-11726047-B2
Publication Date
2023-08-15
Expiration Date
2038-10-02
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Abstract
Materials, methods of making, and methods of sensing liquid droplets with high spatial resolution as a signature of the on-set of corrosion using a hierarchical sensor network A hierarchical sensor network for sensing liquid droplets with high spatial resolution as a signature of the on-set of corrosion, including an interrogation system; and an intermediate sensor array layer in communication with the interrogation system. The network includes an interrogation system and an intermediate sensor array layer in communication with the interrogation system.
Core Innovation
The invention relates to a hierarchical sensor network designed for sensing liquid droplets with high spatial resolution as a signature of the onset of corrosion inside natural gas transmission pipelines. This network integrates an interrogation system with an intermediate sensor array layer, which can be optical fiber based or wireless. The optical fiber sensor array (FSA) comprises a sequence of fiber-optic sensors (FOS) concatenated in two-dimensional configurations such as ring or grid, reflecting the state of the environment. These sensors monitor parameters including water dropwise condensation, dissolved corrosive gases, corrosion product formation, temperature, and stress in steel pipes.
The problem being solved pertains to internal corrosion in natural gas pipelines, particularly Top-of-the-Line Corrosion (TLC), which occurs due to water vapor condensation and the presence of dissolved corrosive substances such as CO2 and H2S. Corrosion inhibitors often fail to mitigate corrosion at the top of pipelines because inhibitors remain at the bottom. Despite dehydration treatments, water condensation and glycol mist carryover introduce corrosive aqueous electrolytes leading to high corrosion rates. The invention provides a high sensitivity, multi-parameter, remote and distributed sensing approach to detect early corrosion onset, precisely localize water droplets, and predict corrosion rates to enable better corrosion control and mitigation.
Claims Coverage
The patent includes one independent method claim and two independent apparatus claims describing hierarchical sensor networks for sensing liquid droplets as corrosion signatures. The main inventive features involve the structure and configuration of the sensor networks and their interrogation systems.
Hierarchical sensor network with functionalized fiber-optic sensors
A sensor network comprising an interrogation system and an intermediate fiber-optic sensor array (FSA) layer with multiple fiber-optic sensors (FOS). Each FOS includes a central sensing fiber region coated with water-sensitive materials selected from polymers, hydrogels, metal-organic frameworks, etc., which alter properties upon water contact to produce an optical response. The FOS further includes two light steering elements and lead-in and lead-out fibers.
Optical time-domain reflectometry (OTDR) interrogation system integration
The interrogation system is optical in nature including an OTDR interrogation system that produces Top-of-the-Line Corrosion (TLC) sensing information. The OTDR includes at least a pulse source, fiber-optic coupler, and photodetector facilitating distributed corrosion sensing along the optical fiber sensor network.
Two-dimensional configuration of fiber-optic sensor arrays
The fiber-optic sensor arrays comprise sequences of FOS concatenated in two-dimensional configurations such as ring or grid. This spatial mapping facilitates high spatial resolution monitoring of droplet condensation and prediction of corrosion rates.
Wireless sensor network alternative
The hierarchical sensor network can alternatively be wireless, comprising passive wireless sensor devices such as surface acoustic wave (SAW) devices distributed throughout the monitored system. These devices are functionalized to detect condensed water presence, relative humidity, and chemistry, and interface with an RF interrogator to provide TLC sensing information.
Method for sensing liquid droplets using hierarchical sensor network
A method involving detecting properties of condensed water using the hierarchical sensor network with the functionalized fiber-optic sensors. Optical changes in the central sensing fiber region caused by water contact are measured to detect presence and chemistry of condensed water as corrosion signatures.
The claims provide comprehensive coverage of a hierarchical sensor network integrating functionalized fiber-optic sensors or passive wireless sensors with interrogation systems for high spatial resolution detection of liquid droplets indicative of corrosion onset and characterization of water condensation to predict corrosion rates.
Stated Advantages
High sensitivity for early detection of corrosion onset through water droplet condensation sensing.
Multi-parameter measurement capability including water droplet size, ionic strength, temperature, and stress.
Remote and distributed sensing allowing spatially resolved evaluation of corrosion tendencies along pipelines.
Ability to provide localized and large-scale monitoring with multiplexed sensor arrays.
Wireless sensor network option enabling flexible and low-cost distributed point measurements.
Documented Applications
Monitoring internal corrosion processes in natural gas transmission pipelines, specifically detecting Top-of-the-Line Corrosion (TLC).
Predicting and quantifying corrosion rates based on water condensation rate measurements inside gas pipelines.
Infrastructure health monitoring in various industrial sectors through distributed sensing of corrosion onset.
Use in pipelines to detect water droplet condensation, dissolved corrosive gas presence, corrosion product formation, and environmental parameters affecting corrosion.
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