Corrosion Sensor Quantification via CFD Wall Shear Stress
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Solution Overview
Problem
Current methods for monitoring corrosion in pressure-containing boundaries of industrial process units, such as petroleum refineries, primarily provide relative corrosion rates, making it difficult to determine the absolute level of corrosion on equipment like pipe walls, which is crucial for timely maintenance and preventing leaks and environmental damage.
Innovation Solution
A method that uses corrosion sensors, like mechanical oscillators, to quantify metal loss by relating sensor output to metal loss on process equipment through computational fluid dynamics (CFD) modeling and calibration with coupons, enabling the determination of absolute corrosion rates on interior surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If corrosion sensors are used to monitor corrosion, then corrosion rate information can be obtained, but only relative corrosion rates are provided making it difficult to determine absolute corrosion levels on equipment
Solution Approach 1:
The patent introduces CFD modeling as an intermediary tool that bridges the gap between sensor measurements and actual equipment corrosion. The CFD model simulates fluid flow and calculates wall shear stress distributions, which are then used to correlate sensor data with predicted corrosion rates on equipment surfaces, enabling absolute corrosion level determination
Solution Approach 2:
The patent replaces direct physical measurement of equipment corrosion with a computational approach. Instead of mechanically measuring corrosion on the equipment itself, the system uses CFD simulations and wall shear stress calculations to predict and determine absolute corrosion levels based on sensor data and flow conditions
2Measurement precision
If CFD modeling with wall shear stress is used to relate sensor corrosion to equipment corrosion, then absolute corrosion rates can be determined, but device complexity increases
Solution Approach 1:
The CFD modeling system serves multiple functions: it simulates fluid flow, calculates wall shear stress distributions, predicts corrosion rates, and correlates sensor measurements with equipment conditions. This multi-functionality reduces the need for separate measurement systems for each parameter
Solution Approach 2:
The patent creates a virtual copy of the equipment interior through CFD modeling. The simulation replicates the fluid flow patterns and wall shear stress conditions that would exist in the actual equipment, allowing corrosion prediction without direct physical measurement on the equipment itself
Data Source
AI summary
A method for determining the amount and rate of corrosion which has occurred on the surface of a process unit by measuring corrosion with a corrosion sensor and measuring at least one parameter inside the process unit. Corrosion on internal surfaces of a process unit can then be determined.