Strain-Tuned Fiber Optic Sensor for Corrosion Monitoring
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Solution Overview
Problem
Current corrosion sensing technologies in petroleum and hydrocarbon processes are inadequate for accurately monitoring metal-loss corrosion rates and corrosive species, as they lack sensitivity, operational reliability, and safety, particularly in high-temperature environments with turbulent multi-phase flows.
Innovation Solution
A fiber optic sensor system utilizing in-fiber gratings, altered and unaltered sensor elements, and strain-tuning elements to measure material alteration through changes in optical reflection spectra, allowing for distributed, sensitive, and reliable detection of corrosion and corrosive species, even in harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional corrosion sensing technologies are used, then the system can monitor corrosion in petroleum processes, but the measurement precision and reliability are insufficient in harsh environments
Solution Approach 1:
The patent replaces conventional electrical or mechanical corrosion sensors with an optical sensing system using fiber optic cables and Bragg gratings. This substitution eliminates the problems of electrical interference and mechanical failure in harsh petroleum processing environments, providing both high measurement precision and reliability for corrosion rate monitoring
Solution Approach 2:
The patent introduces an altered sensor element as an intermediary between the corrosive medium and the measurement system. This element undergoes controlled alteration (corrosion, erosion, or chemical reaction) that produces measurable strain on the fiber optic grating, enabling precise indirect measurement of corrosion rates while protecting the optical sensing components from direct exposure to harsh conditions
2Measurement precision
If the sensor uses altered and unaltered elements with strain-tuning, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The patent divides the sensor into distinct functional segments: an altered sensor element that interacts with the medium, an unaltered reference element, strain-tuning elements for calibration, and the optical fiber with Bragg grating for measurement. This segmentation allows each component to be optimized independently while maintaining overall system precision without excessive complexity
Solution Approach 2:
The patent utilizes controlled parameter changes in the altered sensor element (such as dimensional changes from corrosion or erosion) that translate into strain variations measurable by the Bragg grating. By monitoring these parameter changes through optical reflection spectrum shifts, the system achieves high measurement precision while the complexity remains manageable through passive physical transformations
3Productivity
If the sensor monitors multiple parameters continuously, then the productivity improves, but the loss of energy increases
Solution Approach 1:
The patent employs a passive optical sensing mechanism where the Bragg grating reflects specific wavelengths of light based on the strain it experiences from material alteration. The system requires minimal active energy input for measurement, as the optical properties change automatically in response to environmental conditions, enabling continuous multi-parameter monitoring with low energy consumption
Solution Approach 2:
The patent enables continuous monitoring of corrosion rates, erosive species, and other material alteration parameters through the persistent optical interaction between the fiber optic grating and the altered sensor element. The system maintains constant surveillance capability without periodic interruption, maximizing productivity while the low power requirement of optical sensing minimizes energy loss
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 accurate monitoring of metal-loss corrosion rates and corrosive species, improving equipment reliability and operational efficiency by providing continuous, sensitive, and reliable data on material alteration, extending the operational lifetime of equipment and reducing unplanned shutdowns.
Implementation Method 1
one or more in-fiber gratings, such as Bragg gratings, that are produced within the optical fiber... reflected from the grating... Measurement of this peak reflectivity wavelength can be related to the local temperature and strain at the grating
Implementation Method 2
detection of material alteration by processes that alter the dimensions, strength, and thermal and mechanical properties of the altered sensor element material. Examples of such material alteration processes are: corrosion, erosion, absorption, deposition, solubilization, dissolution, reaction, or vaporization by constituents of the medium
Data Source
AI summary
The present invention includes a method and system of measuring alteration, alteration type, and alteration-causing species in process fluids and equipment and for controlling the process feeds and conditions to maximize the yields and equipment lifetime by minimizing the alteration. The invention includes an optical sensor comprising an optical fiber, a fiber grating written within the optical fiber, strain-tuned elements fixed to the optical fiber and an unaltered element, and an altered element fixed to the unaltered element.