Patent Publication Number: US-2023135104-A1

Title: System and method using sensors embedded on tape for corrosion monitoring

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure relates generally to corrosion sensors, and, more particularly, to a system and method using sensors for corrosion monitoring. 
     BACKGROUND OF THE DISCLOSURE 
     Corrosion of wells, pipelines, and casings in the oil and gas industry can jeopardize the integrity of upstream and downstream assets. Different methods can be used to detect corrosion. Indirect measurements such as lab analysis and pressure tests are typically limited to evaluations at surface conditions, and so are not useful for sub-surface tests for corrosion of underground structures. Direct measurements such as by ultrasonic testing, electromagnetic flux testing, and probes are typically expensive to perform. In addition, such tests and probes are complex to deploy for accurate evaluations. Another type of test relies on the use of coupons, which insert an in-line intrusive corrosion monitoring device for direct contact with corrosive fluids and for monitoring long term performance of structures. However, the use of coupons can be expensive and typically have low resolution of detection of corrosion and corrosion rate. 
     SUMMARY OF THE DISCLOSURE 
     According to an embodiment consistent with the present disclosure, a system and method use a sensor embedded in a flexible tape which monitors for corrosion of a structure, such as a conveyance line in a well. 
     In an embodiment, a system comprises a structure, a spool, a flexible tape, a sensor, a spool driver, and a processor. The structure includes a window adjacent to an element under test. The flexible tape is retained by the spool. The sensor is embedded in the tape, with the sensor being configured to detect a corrosion of the element and to generate corresponding sensor data. The spool driver is coupled to the spool and is operative to advance the tape from the spool to position the sensor adjacent to the window, thereby to position the sensor adjacent to the element to detect the corrosion. The processor is configured by code stored therein to receive the sensor data and to generate and output an alert of the detected corrosion. 
     The sensor can be selected from the group consisting of, but not limited to: a chemical sensor, an organic sensor, and a polyethylene terephthalate (PET) sensor. The tape advances from the spool in a direction relative to the structure, with the direction being selected from the group consisting of: a horizontal direction, a vertical direction, a diagonal direction, an inline-longitudinal direction, an inline-azimuthal direction, a parallel-longitudinal direction, and a parallel-azimuthal direction. The processor includes a data acquisition unit configured to receive the sensor data, a data analysis unit configured to generate the alert from the sensor data, and a data communication unit configured to output the alert to an external system. The data analysis unit formats the alert to be in a predetermined communication format. The data analysis unit can also format the sensor data to be in a predetermined communication format, and the data communication unit can be configured to output the formatted sensor data to the external system. The external system is an output device configured to output the alert or the sensor data. 
     In another embodiment, a system comprises a conveyance line in a well, a spool, a flexible tape retained by the spool, a plurality of sensors, a spool driver, and a processor. The plurality of sensors are embedded in and distributed along the tape, wherein the plurality of sensors are configured to detect a corrosion of the conveyance line and to generate corresponding sensor data. The spool driver is coupled to the spool and is operative to advance the tape from the spool to position the plurality of sensors adjacent to the conveyance line. The processor is configured by code stored therein to receive the sensor data, and to generate and output an alert of the detected corrosion. 
     Each of the plurality of sensors can be selected from the group consisting of: a chemical sensor, an organic sensor, and a polyethylene terephthalate (PET) sensor. The tape advances from the spool in a direction relative to the conveyance line, with example of the direction being selected from the group consisting of: a horizontal direction, a vertical direction, a diagonal direction, an inline-longitudinal direction, an inline-azimuthal direction, a parallel-longitudinal direction, and a parallel-azimuthal direction. The processor includes a data acquisition unit configured to receive the sensor data, a data analysis unit configured to generate the alert from the sensor data, and a data communication unit configured to output the alert to an external system. The data analysis unit formats the alert to be in a predetermined communication format. The data analysis unit can also format the sensor data to be in a predetermined communication format, and the data communication unit is configured to output the formatted sensor data to the external system. The external system is an output device configured to output the alert or the sensor data. 
     In a further embodiment, a method comprises providing a structure including a window adj acent to an element under test, retaining a flexible tape having an embedded sensor with a spool, advancing the tape from the spool to position the sensor adj acent to the window, thereby to position the sensor adjacent to the element to detect the corrosion and to generate corresponding sensor data, receiving the sensor data at a processor, generating an alert of the detected corrosion, and outputting the alert to an external system. 
     The sensor can be selected from the group consisting of, but not limited to: a chemical sensor, an organic sensor, and a polyethylene terephthalate (PET) sensor. The tape advances from the spool in a direction relative to the structure, with example of the direction being selected from the group consisting of: a horizontal direction, a vertical direction, a diagonal direction, an inline-longitudinal direction, an inline-azimuthal direction, a parallel-longitudinal direction, and a parallel-azimuthal direction. The method further comprises outputting the sensor data to the external system or to a memory. The processor includes a data acquisition unit configured to receive the sensor data, a data analysis unit configured to generate the alert from the sensor data, and a data communication unit configured to output the alert to the external system. The external system is an output device configured to output the alert or the sensor data. 
     Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic of deployment of sensors from a spool into a well, according to an embodiment. 
         FIG.  2    is a schematic of an alternative deployment of sensors from a spool. 
         FIG.  3    is an example of a sensor. 
         FIG.  4    is a tape having embedded sensors as in  FIG.  3   . 
         FIG.  5    shows spooling of a tape having embedded sensors in a first orientation. 
         FIG.  6    shows spooling of a tape having embedded sensors in a second orientation. 
         FIG.  7    shows spooling of a tape having embedded sensors in a third orientation. 
         FIG.  8    shows spooling of a tape having embedded sensors in a fourth orientation. 
         FIG.  9    is a logging tool with a tape having embedded sensors distributed thereon. 
         FIG.  10    is a logging tool wrapped with a tape having embedded sensors. 
         FIG.  11    is a logging tool with adjacent tapes having embedded sensors. 
         FIG.  12    is a flowchart of a method of use of a tape having embedded sensors. 
     
    
    
     It is noted that the drawings are illustrative and are not necessarily to scale. 
     DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THE DISCLOSURE 
     Example embodiments consistent with the teachings included in the present disclosure are directed to a system  10  and method  100  using a sensor embedded in a flexible tape which monitors for corrosion of a structure, such as a conveyance line in a well or pipeline. 
     As shown in  FIG.  1   , the system  10  includes a spool  12  of the flexible tape  14  having the sensor embedded therein. The flexible tape  14  advances from the spool  12  adjacent to a data acquisition unit  16 . The data acquisition unit  16  is a hardware processor storing code therein configured to acquire sensor data from the sensor embedded in the flexible tape  14 . The flexible tape  14  further advances into a well  18  along a conveyance line  20  that is shown extending into a borehole of the well  18 . The conveyance line can be a wireline, slickline, fiber-line, drill-pipe, tubing, coiled-tubing, or other structures extending through a well, pipeline, or casing. The conveyance line  20  ends at a terminating member  22 . The terminating member  22  can be a weight bar. Alternatively, the terminating member  22  can be a logging tool. Still further, the terminating member  22  can be a memory sub. In any of these arrangements, the terminating member has a weight to assist the tape in advancing down into the borehole. 
     In an alternative embodiment illustrated in  FIG.  2   , the system  30  includes sensor spools  32 ,  34 , with a sensor tape  36  advancing from the sensor spool  32  to the sensor spool  34  through the use of at least one spool driver  38  (only one illustrated), but a driver can be provided for each sensor spool. The sensor tape  36  is a flexible tape having a sensor embedded therein. The sensor tape  36  with the sensor is advanced to a sensor window  40  to be positioned adjacent to an element under test  42 . The sensor on the sensor tape  36  generates sensor data corresponding to the state of the element under test, such as corrosion. The corrosion can be detected by the presence of hydrogen (H). Also, the corrosion can be detected by the presence of carbon dioxide (CO 2 ). In addition, the corrosion can be detected by the presence of hydrogen sulfide (H 2 S). Furthermore, the corrosion can be detected by the presence of chlorine (Cl). Still further, the corrosion can be detected by the presence of iron (Fe). 
     Common to both arrangements of  FIGS.  1  and  2   , such sensor data is sent to a data acquisition unit  44 . The data acquisition unit  44  is a hardware processor storing code therein configured to acquire the sensor data from the sensor embedded in the flexible sensor tape  36 . The data acquisition unit  44  transmits the sensor data to a data analysis unit  46 . The data analysis unit  46  is a hardware processor storing code therein configured to generate an alert from the sensor data. The data analysis unit  46  formats the alert to be in a predetermined communication format. The data analysis unit  46  transmits the formatted alert to a data communication unit  48 . The data communication unit  48  is a hardware processor storing code therein and configured to output the alert to an external system. The external system is an output device configured to output the alert or the sensor data. The external system can be a surface system  50 . The surface system  50  can further process the alert or the sensor data. Alternatively, the external system can be a memory  52  configured to store the alert or the sensor data to be available for later processing and analysis. 
     Referring to  FIG.  3   , the sensor  62  comprises a chemical sensor. In certain embodiments, the chemical sensor can be made of synthetic zinc oxide (ZnO) nanostructures that are grown on a zeolite substrate to detect corrosion species. Alternatively, the sensor  62  can be an organic sensor. The organic sensor can be disposed on organic semiconductors or conductive organic materials. Furthermore, the sensor  62  can be a polyethylene terephthalate (PET) sensor. The PET sensor can detect gases. 
     As shown in  FIG.  4   , the sensor tape  36  is a flexible tape having at least one sensor  62  of one or multiple types embedded therein. Referring to  FIGS.  5 - 8   , the sensor tape  36  can be spooled on the spools  32 ,  34  to advance the tape  36  to position the at least one sensor  62  adjacent to the sensor window  40 . As shown in the schematic views provided in  FIGS.  5 - 8   , the tape advances from the spool  32  in a direction relative to the structure such as the element under test  42 . As illustrated in  FIG.  5   , the direction is a horizontal direction. Alternatively, the direction is an inline-longitudinal direction. As illustrated in  FIG.  6   , the direction is a vertical direction. Alternatively, the direction is an inline-azimuthal direction. As shown in  FIGS.  7 - 8   , direction is a diagonal direction. As illustrated in  FIG.  7   , the direction is a parallel-longitudinal direction. As illustrated in  FIG.  8   , the direction is a parallel-azimuthal direction. 
     Referring to  FIG.  9   , a logging tool  70  has a structure  72  as the element under test. The structure  72  can optionally rotate about an axis  74 . As the structure rotates, various sensors  62  on respective tapes  36  are positioned horizontally adjacent to the surface of the structure  72  to detect corrosion at specific locations on the structure  72 . In alternative embodiments, as shown in  FIGS.  10 - 11   , the tapes  36  having sensors  62  embedded therein can be spooled about the surface of the structures to detect corrosion. Referring to  FIG.  10   , a logging tool  80  can have a structure  82  with tape  36  spooled helically adjacent to the structure  82 . Referring to  FIG.  11   , a logging tool  90  can have a structure  92  with different tapes  94 ,  96 ,  98  spooled vertically adjacent to the structure  92 . As with the logging tool  70  in  FIG.  9   , the logging tools  80 ,  90  in  FIGS.  10 - 11   , respectively, can rotate. Such rotation allows the sensors  62  to be positioned adjacent to different regions on the structures  82 ,  92 , to detect for corrosion at different locations on the logging tools  80 ,  90 , respectively. 
     As shown in  FIG.  12   , the method  100  of operation of the systems  10 ,  30  include moving or advancing a tape  36  having embedded sensors  62  out of or from a spool  32  in step  102 , and moving or positioning the embedded sensor  62  on the tape  36  to a sensor window  40  adjacent to an element  42  under test in step  104 . Then data is acquired from the embedded sensor  62  at the sensor window  40  in step  106 , and the acquired data is analyzed in step  108 . The analyzed data is formatted in step  110  in a conventional manner to meet the requirements of an external system. For instance, the data can be formatted into a spreadsheet and saved so as to be compatible with Microsoft Excel, or saved as a comma-separated values table, text file, and so on. Alternatively, the data can be saved in data value pairs and saved in a list. The formatted data is transmitted to an external system  50  or memory  52  in step  112 . The method  100  then generates and outputs an alert of corrosion of the element  42  under test using the formatted data in step  114 . 
     In an alternative arrangement, the system and method described herein can have a sensor as previously described embedded in the conveyance line within a well or, alternatively, in a surface structure. In these arrangements, the sensor still monitors for corrosion of a structure, but is mounted in a different position. 
     Portions of the methods described herein can be performed by software or firmware in machine readable form on a tangible (e.g., non-transitory) storage medium. For example, the software or firmware can be in the form of a computer program including computer program code adapted to cause the system to perform various actions described herein when the program is run on a computer or suitable hardware device, and where the computer program can be embodied on a computer readable medium. Examples of tangible storage media include computer storage devices having computer-readable media such as disks, thumb drives, flash memory, and the like, and do not include propagated signals. Propagated signals can be present in a tangible storage media. The software can be suitable for execution on a parallel processor or a serial processor such that various actions described herein can be carried out in any suitable order, or simultaneously. 
     It is to be further understood that like or similar numerals in the drawings represent like or similar elements through the several figures, and that not all components or steps described and illustrated with reference to the figures are required for all embodiments or arrangements. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “contains”, “containing”, “includes”, “including,” “comprises”, and/or “comprising,” and variations thereof, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     Terms of orientation are used herein merely for purposes of convention and referencing and are not to be construed as limiting. However, it is recognized these terms could be used with reference to an operator or user. Accordingly, no limitations are implied or to be inferred. In addition, the use of ordinal numbers (e.g., first, second, third) is for distinction and not counting. For example, the use of “third” does not imply there is a corresponding “first” or “second.” Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
     While the disclosure has described several exemplary embodiments, it will be understood by those skilled in the art that various changes can be made, and equivalents can be substituted for elements thereof, without departing from the spirit and scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation, or material to embodiments of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, or to the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 
     The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes can be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the invention encompassed by the present disclosure, which is defined by the set of recitations in the following claims and by structures and functions or steps which are equivalent to these recitations.