Hybrid Sensor for HTHA Detection
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Solution Overview
Problem
Current inspection techniques for High Temperature Hydrogen Attack (HTHA) in the oil and gas industry are inadequate for early detection and assessing damage progression, particularly in harsh environments, due to limitations in identifying hydrogen damage and determining crack presence and extent.
Innovation Solution
The use of removable sensors with adaptable hybrid pads and advanced materials like MXenes for capturing surface data, including temperature, pH, and methane measurements, to detect cracks and predict HTHA susceptibility, combined with Pulsed Eddy Current (PEC) and pH sensors for continuous monitoring and risk-based inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic techniques are used for HTHA detection, then inspection can be performed on equipment, but the detection precision is insufficient to identify hydrogen damage and determine crack presence
Solution Approach 1:
The patent combines multiple sensing modalities (ultrasonic sensors, temperature sensors, pH sensors, and methane sensors) into an integrated hybrid sensor system. This merging of different detection technologies enables simultaneous measurement of multiple parameters (acoustic emissions, thermal conditions, chemical environment, and gas presence) to comprehensively detect HTHA damage with higher precision while managing system complexity through integrated design.
Solution Approach 2:
The hybrid sensor system is designed to perform multiple functions: detecting acoustic emissions from cracks, monitoring temperature conditions, measuring pH levels at the crack tip, and detecting methane gas presence. This multi-functionality allows a single inspection system to gather comprehensive data about HTHA damage progression without requiring separate specialized equipment for each measurement type.
2Reliability
If removable sensors with adaptable hybrid pads are used, then early prediction and continuous monitoring of HTHA is enabled, but the device complexity increases
Solution Approach 1:
The sensor system employs adaptable hybrid pads that can dynamically adjust to different equipment surfaces and geometries. These pads incorporate flexible mounting mechanisms and reconfigurable sensor arrays that can be adapted to various inspection locations on pressure vessels, heat exchangers, and piping equipment, enabling reliable continuous monitoring while managing complexity through modular and reconfigurable design.
Solution Approach 2:
The sensor system includes self-diagnostic capabilities and automated data analysis features that reduce the need for complex external monitoring infrastructure. The sensors can autonomously detect HTHA conditions, process the collected data, and generate alerts, thereby improving reliability through self-monitoring while reducing the operational complexity of the overall inspection system.
3Measurement precision
If multiple measurement parameters (temperature, pH, methane) are captured, then early signs of methane formation and crack propagation are detected, but the measurement system complexity increases
Solution Approach 1:
The patent integrates temperature sensors, pH sensors, and methane sensors into a single hybrid sensor assembly that can simultaneously measure all three parameters at the same location. This merging of sensing capabilities within one integrated unit enables comprehensive detection of HTHA indicators (temperature conditions, chemical environment at crack tip, and methane gas presence) with high accuracy while reducing the complexity compared to using separate sensor systems.
Solution Approach 2:
The adaptable hybrid pads serve as intermediaries between the multiple sensor types and the equipment surface. These pads provide a unified mounting interface and signal processing platform that simplifies the integration of diverse sensors, enabling simultaneous multi-parameter measurement while managing the complexity of connecting and coordinating multiple sensor types through a standardized intermediate interface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables early prediction and continuous monitoring of HTHA, providing accurate assessment of crack propagation and asset integrity, even in harsh environments, through adaptable and online sensing solutions.
Implementation Method 1
Surface data is captured using the removable sensors. The surface data includes surface temperatures, per hydrogen (Ph) measurements, and methane measurements
Implementation Method 2
The surface data includes surface temperatures, per hydrogen (Ph) measurements, and methane measurements for methane escaping from external surfaces of the equipment
Implementation Method 3
The surface data includes surface temperatures
Implementation Method 4
A presence of cracks in the equipment base metal is determined using the surface data
Data Source
AI summary
Systems and methods include a computer-implemented method for inspection. Removable sensors are installed on equipment used in hydrocarbon facilities at locations susceptible to high temperature hydrogen attack (HTHA). Attachment uses adaptable hybrid pads. Surface data captured using the sensors includes surface temperatures, per hydrogen (Ph) measurements, and methane measurements for methane escaping from external surfaces of the equipment. A presence of cracks in the equipment base metal is determined. An HTHA susceptibility analysis of the equipment is performed based on the presence of the cracks and by analyzing the surface data and mapping potential HTHA cracks and early signs of methane formation. The steps are repeated on other locations. An inspection result and assessment, generated using the captured surface data, includes a final analysis of assessment reports indicating a likelihood of cracks propagation and a presence of fissuring inside the equipment base metal.