Academic literature on the topic 'Novel Corrosion Sensing'
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Journal articles on the topic "Novel Corrosion Sensing"
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Yang, Dan, Xinyi Zhang, Ti Zhou, Tao Wang, and Jiahui Li. "A Novel Pipeline Corrosion Monitoring Method Based on Piezoelectric Active Sensing and CNN." Sensors 23, no. 2 (January 11, 2023): 855. http://dx.doi.org/10.3390/s23020855.
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In this study, a piezoelectric active sensing-based time reversal method was investigated for monitoring pipeline internal corrosion. An effective method that combines wavelet packet energy with a Convolutional Neural Network (CNN) was proposed to identify the internal corrosion status of pipelines. Two lead zirconate titanate (PZT) patches were pasted on the outer surface of the pipeline as actuators and sensors to generate and receive ultrasonic signals propagating through the inner wall of the pipeline. Then, the time reversal technique was employed to reverse the received response signal in the time domain, and then to retransmit it as an excitation signal to obtain the focused signal. Afterward, the wavelet packet transform was used to decompose the focused signal, and the wavelet packet energy (WPE) with large components was extracted as the input of the CNN model to rapidly identify the corrosion degree inside the pipeline. The corrosion experiments were conducted to verify the correctness of the proposed method. The occurrence and development of corrosion in pipelines were generated by electrochemical corrosion, and nine different depths of corrosion were imposed on the sample pipeline. The experimental results indicated that the classification accuracy exceeded 99.01%. Therefore, this method can quantitatively monitor the corrosion status of pipelines and can pinpoint the internal corrosion degree of pipelines promptly and accurately. The WPE-CNN model in combination with the proposed time reversal method has high application potential for monitoring pipeline internal corrosion.
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Bartelmess, Juergen, David Zimmek, Matthias Bartholmai, Christoph Strangfeld, and Michael Schäferling. "Fibre optic ratiometric fluorescence pH sensor for monitoring corrosion in concrete." Analyst 145, no. 6 (2020): 2111–17. http://dx.doi.org/10.1039/c9an02348h.
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Kaur, Baljinder, Santosh Kumar, and Brajesh Kumar Kaushik. "Novel Wearable Optical Sensors for Vital Health Monitoring Systems—A Review." Biosensors 13, no. 2 (January 23, 2023): 181. http://dx.doi.org/10.3390/bios13020181.
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Wearable sensors are pioneering devices to monitor health issues that allow the constant monitoring of physical and biological parameters. The immunity towards electromagnetic interference, miniaturization, detection of nano-volumes, integration with fiber, high sensitivity, low cost, usable in harsh environments and corrosion-resistant have made optical wearable sensor an emerging sensing technology in the recent year. This review presents the progress made in the development of novel wearable optical sensors for vital health monitoring systems. The details of different substrates, sensing platforms, and biofluids used for the detection of target molecules are discussed in detail. Wearable technologies could increase the quality of health monitoring systems at a nominal cost and enable continuous and early disease diagnosis. Various optical sensing principles, including surface-enhanced Raman scattering, colorimetric, fluorescence, plasmonic, photoplethysmography, and interferometric-based sensors, are discussed in detail for health monitoring applications. The performance of optical wearable sensors utilizing two-dimensional materials is also discussed. Future challenges associated with the development of optical wearable sensors for point-of-care applications and clinical diagnosis have been thoroughly discussed.
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Nazir, Mian Hammad, Zulfiqar A. Khan, and Adil Saeed. "A Novel Non-Destructive Sensing Technology for On-Site Corrosion Failure Evaluation of Coatings." IEEE Access 6 (2018): 1042–54. http://dx.doi.org/10.1109/access.2017.2777532.
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Ye, X. W., Y. H. Su, and J. P. Han. "Structural Health Monitoring of Civil Infrastructure Using Optical Fiber Sensing Technology: A Comprehensive Review." Scientific World Journal 2014 (2014): 1–11. http://dx.doi.org/10.1155/2014/652329.
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In the last two decades, a significant number of innovative sensing systems based on optical fiber sensors have been exploited in the engineering community due to their inherent distinctive advantages such as small size, light weight, immunity to electromagnetic interference (EMI) and corrosion, and embedding capability. A lot of optical fiber sensor-based monitoring systems have been developed for continuous measurement and real-time assessment of diversified engineering structures such as bridges, buildings, tunnels, pipelines, wind turbines, railway infrastructure, and geotechnical structures. The purpose of this review article is devoted to presenting a summary of the basic principles of various optical fiber sensors, innovation in sensing and computational methodologies, development of novel optical fiber sensors, and the practical application status of the optical fiber sensing technology in structural health monitoring (SHM) of civil infrastructure.
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Savill, Tim, Eifion Jewell, and Peter Barker. "Development of Techniques and Non-Destructive Methods for in-Situ Performance Monitoring of Organically Coated Pre-Finished Cladding Used in the Construction Sector." ECS Meeting Abstracts MA2022-01, no. 16 (July 7, 2022): 1016. http://dx.doi.org/10.1149/ma2022-01161016mtgabs.
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Asset corrosion is a huge problem for the construction and other industries with an estimated cost of approximately GBP 300 billion in the EU in 2013 [1]. To mitigate this cost and protect metal substrates from corrosion, organic coatings are often used. In 2017 the EU produced 4 million metric tonnes of organically coated steel, a large quantity of which is used for the production of building cladding material [2]. Cladding material is widely used in construction of both commercial, industrial, and residential buildings due to its convenience, speed of construction as well as aesthetic and weather resistant properties. Architects and customers are increasingly using pre-finished coated steel panels to provide a sleek modern design. In order to maintain the required aesthetic value offered by these panels, it is of crucial importance that the coatings provide appropriate protection from the harsh conditions faced by building facades. It is paramount that manufacturers of the cladding can provide reassurances of the long-term coating performance to provide confidence to the end customer. Despite this, coating performance is only currently estimated by accelerated lab-based tests and some short-term outdoor exposure testing. These tests are carried out in conditions that produce results that are often not representative of real life, leading to earlier than expected failure of the product in some conditions. The ability to monitor the environments that the coatings are exposed to, as well as the actual real-time performance of the coating itself, would provide a far better avenue to determine the expected lifetime of the coated product as well as maintenance scheduling and failure prevention. Furthermore, it would reduce the requirement for human inspection and allow remedial maintenance before the damage becomes too significant to warrant replacement. The advantages of in-situ, real time monitoring has long been recognized by the oil and gas industry, however, at this point in time they are the only sector deploying significant corrosion and coating monitoring techniques. However, as we move to a more connected world, with an increase in devices and IOT systems there is increased interest by the construction section in sensing. There has been significant research effort to develop corrosion sensing of concrete embedded rebar [3–5] and it is clear there is an appetite to grow the field of asset monitoring. The research undertaken develops novel deployments of existing techniques as well as new techniques to detect both corrosion of metallic substrates and degradation and failure of the organic coatings. The overall aim is to produce a sensor system that can work autonomously over long periods. This presented difficulties in terms of, powering, communication, durability, deployment, and sensitivity. The ideas explored include capacitive based sensing, magnetic flux leakage, RFID EMI based corrosion sensing and radiofrequency based dielectric sensing. The designed sensors show promise in detecting early stages of corrosion and coating failure as well as indicating the severity of such changes. The work presented will discuss the challenges faced and how they were/are being overcome as well as the current sensor development and results. Koch GH, Varney J, Thompson N, Moghissi O, Gould M, et al. (2012) International measures of prevention, application, and economics of corrosion technologies study. NACE International, Houston. Eurofer. European Steel in Figures 2008-2017. 2018. James A, Bazarchi E, Chiniforush AA, Panjebashi Aghdam P, Hosseini MR, Akbarnezhad A, et al. Rebar corrosion detection, protection, and rehabilitation of reinforced concrete structures in coastal environments: A review. Constr Build Mater [Internet]. 2019;224:1026–39. Available from: https://www.sciencedirect.com/science/article/pii/S0950061819319208 Xie L, Zhu X, Liu Z, Liu X, Wang T, Xing J. A rebar corrosion sensor embedded in concrete based on surface acoustic wave. Measurement [Internet]. 2020;165:108118. Available from: https://www.sciencedirect.com/science/article/pii/S0263224120306564 Fan L, Shi X. Techniques of corrosion monitoring of steel rebar in reinforced concrete structures: A review. Struct Heal Monit [Internet]. 0(0):14759217211030912. Available from: https://doi.org/10.1177/14759217211030911
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Yang, Mingzhang, and Jing Liu. "In Situ Monitoring of Corrosion under Insulation Using Electrochemical and Mass Loss Measurements." International Journal of Corrosion 2022 (January 10, 2022): 1–12. http://dx.doi.org/10.1155/2022/6681008.
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Corrosion under insulation (CUI) refers to the external corrosion of piping and vessels when they are encapsulated in thermal insulation. To date, very limited information (especially electrochemical data) is available for these “difficult-to-test” CUI conditions. This study was aimed at developing a novel electrochemical sensing method for in situ CUI monitoring and analysis. Pt-coated Ti wires were used to assemble a three-electrode electrochemical cell over a pipe surface covered by thermal insulation. The CUI behavior of X70 carbon steel (CS) and 304 stainless steel (SS) under various operating conditions was investigated using mass loss, linear polarization resistance (LPR), and electrochemical impedance spectroscopy (EIS) measurements. It was found that both the consecutive wet and dry cycles and cyclic temperatures accelerated the progression of CUI. LPR and EIS measurements revealed that the accelerated CUI by thermal cycling was due to the reduced polarization resistance and deteriorated corrosion film. Enhanced pitting corrosion was observed on all tested samples after thermal cycling conditions, especially for CS samples. The proposed electrochemical technique demonstrated the ability to obtain comparable corrosion rates to conventional mass loss data. In addition to its potential for in situ CUI monitoring, this design could be further applied to rank alloys, coatings, and inhibitors under more complex exposure conditions.
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Fadaie, Sina, Moura Mehravar, David John Webb, and Wei Zhang. "Nearshore Contamination Monitoring in Sandy Soils Using Polymer Optical Fibre Bragg Grating Sensing Systems." Sensors 22, no. 14 (July 12, 2022): 5213. http://dx.doi.org/10.3390/s22145213.
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Civil engineering assets and geo-structures continually deteriorate during their lifetime, particularly in harsh environments that may be contaminated with corrosive substances. However, efficient and constant structural health monitoring and accurate prediction of the service-life of these assets can help to ensure their safety, performance, and health conditions and enable proper maintenance and rehabilitation. Nowadays, many of the largest cities throughout the world are situated in coastal zones, leading to a dramatic increase in the construction of nearshore geo-structures/infrastructures which are vulnerable to corrosion attacks resulting from salinity contamination. Additionally, seawater intrusion can threaten the quality and the sustainability of fresh groundwater resources, which are a crucial resource in coastal areas. To address these issues, detection of salinity in soil utilizing a novel polymer optical fibre Bragg grating (POFBG) sensor was investigated in this research. Experiments were carried out at different soil water contents with different salinities to assess the sensor’s response in a representative soil environment. The sensitivity of the POFBG sensor to salinity concentrations in water and soil environment is estimated as 58 ± 2 pm/%. The average standard error value in salinity is calculated as 0.43% for the samples with different soil water contents. The results demonstrate that the sensor is a promising and practical tool for the measurement and monitoring with high precision of salinity contamination in soil.
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Sedighi, Sina, Marcelo A. Soto, Alin Jderu, Dorel Dorobantu, Marius Enachescu, and Dominik Ziegler. "Swelling-Based Distributed Chemical Sensing with Standard Acrylate Coated Optical Fibers." Sensors 21, no. 3 (January 21, 2021): 718. http://dx.doi.org/10.3390/s21030718.
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Distributed chemical sensing is demonstrated using standard acrylate coated optical fibers. Swelling of the polymer coating induces strain in the fiber’s silica core provoking a local refractive index change which is detectable all along an optical fiber by advanced distributed sensing techniques. Thermal effects can be discriminated from strain using uncoated fiber segments, leading to more accurate strain readings. The concept has been validated by measuring strain responses of various aqueous and organic solvents and different chain length alkanes and blends thereof. Although demonstrated on a short range of two meters using optical frequency-domain reflectometry, the technique can be applied to many kilometer-long fiber installations. Low-cost and insensitive to corrosion and electromagnetic radiation, along with the possibility to interrogate thousands of independent measurement points along a single optical fiber, this novel technique is likely to find applications in environmental monitoring, food analysis, agriculture, water quality monitoring, or medical diagnostics.
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Nishiyama, M., H. Sasaki, S. Nose, K. Takami, and K. Watanabe. "Distributed Pressure Sensing as Smart Mat Applications with Hetero-Core Fiber Optic Nerve Sensors." Advanced Materials Research 47-50 (June 2008): 391–94. http://dx.doi.org/10.4028/www.scientific.net/amr.47-50.391.
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Distributed pressure sensing schemes for human positioning and plantar mapping is desired to be unconstrained for human activity in their daily life in the form of a floor and mat. On the other hand, an optical fiber has several advantages such as lightweight, minimal material, and resistance to corrosion and electromagnetic interference. Additionally, a novel hetero-core optic fiber nerve sensor is only sensitive to be bending action of the sensor portion and the fiber transmission line is unaffected to external disturbance as pressure and temperature fluctuation because of its single-mode stable propagation scheme. Therefore, the hetero-core fiber optic sensor could be suitable for the distributed pressure sensing in human natural activity and be placed in various sites. In this paper, we proposed several smart mat applications in the form of a thin mat in the floor for human positioning and sole pressure mapping mat using the hetero-core optic fiber sensors. We successfully demonstrated the distributed pressure sensing mat using hetero-core sensors to detect human positioning with their circumstance and sole pressure mapping.
Conference papers on the topic "Novel Corrosion Sensing"
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Loh, Kenneth J., and Jerome P. Lynch. "Design and Validation of Carbon Nanotube Thin Film Wireless Sensors for pH and Corrosion Monitoring." In ASME 2008 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. ASMEDC, 2008. http://dx.doi.org/10.1115/smasis2008-569.
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Corrosion damage in civil, aeronautical, and mechanical systems poses significant risks to users and occupants while simultaneously burdening owners with costly repairs and maintenance. Although many different sensing technologies are available to monitor corrosion processes, many cannot be easily implemented in field environments due to requiring expensive data acquisition systems and their destructive and intrusive measurement strategies. In this study, a novel layer-by-layer assembled carbon nanotube and poly(aniline)-based nanocomposite pH sensor is developed for monitoring corrosion of metallic and reinforced concrete structures. First, the electrochemical response of the proposed nanocomposite pH sensor is characterized using time-domain two-point resistance probing measurements to validate its resistance change to different pH buffer solutions (1 to 13). Frequency-domain electrical impedance spectroscopic studies and equivalent circuit analyses confirm changes in film resistance to pH. Upon sensor characterization, these nanocomposites are directly deposited onto printed circuit board coil antennas to realize a miniature passive wireless sensor capable of being embedded within structural materials. Preliminary wireless pH sensing results are presented to demonstrate that the wireless sensor’s bandwidth decreases at 3.9 kHz-pH−1 with increasing pH.
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Nott, Phil, William Shepherd, John McNab, Phil Harley, and Syed Zakir Ahmed. "A Novel Electrical Based Breach Detection System for Flexible Pipe." In ASME 2016 35th International Conference on Ocean, Offshore and Arctic Engineering. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/omae2016-54781.
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An outer shield breach is the most common form of damage that can occur to a subsea flexible pipe during both installation and operation. Definitive and accurate detection and location of such damage is imperative in triggering the appropriate repair response. The overall aim is to minimise corrosion damage to the carbon steel strength elements in the pipe annulus, which occurs from the resulting ingress of seawater. GE Oil & Gas, in collaboration with Photon Fire Ltd have developed a new method of detecting seawater in a subsea flexible pipe annulus. This paper describes a novel breach detection system developed to monitor pipes using very low energy electrical signals appropriate for use in hazardous areas. The technique provides an enduring record of the occurrence of a breach and the extent of the subsequent flooding. A brief outline of the development programme is presented. The work involved determining the sensing technique used, development of appropriate electronic instrumentation, the optimised method for installing the sensor into the riser, and bespoke connection to the instrumentation. A prototype system, approved for use in Hazardous Area ATEX zone zero has been implemented on midscale pipe samples and the transient and steady state ‘scans’ of the pipe have been investigated. A summary of the test results and a proposed testing regime is presented. Results show that using this technique can accurately determine that a breach has occurred in the wall of the riser and the extent of the flooding.
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Northcutt, Robert, Jacob Maddox, and Vishnu-Baba Sundaresan. "Electrode Fabrication for Scanning Electrochemical Microscopy and Shear Force Imaging." In ASME 2016 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/smasis2016-9155.
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The development of novel characterization techniques is critical for understanding the fundamentals of material systems. Bioinspired systems are regularly implemented but poorly defined through quantitative measurement. In an effort to specify the coupling between multiple domains seen in biologically inspired systems, high resolution measurement systems capable of simultaneously measuring various phenomena such as electrical, chemical, mechanical, or optical signals is required. Scanning electrochemical microscopy (SECM) and shear-force (SF) imaging are nanoscale measurement techniques which examine the electrochemical behavior at a liquid-solid or liquid-liquid interface and simultaneously probe morphological features. It is therefore a suitable measurement technique for understanding biological phenomena. SF imaging is a high resolution technique, allowing for nanoscale measurement of extensional actuation in materials with high signal to noise ratio. The sensing capabilities of SECM-SF techniques are dependent on the characteristics of the micro-scale electrodes (ultramicroelectrodes or UMEs) used to investigate surfaces. Current limitations to this technique are due to the fabrication process which introduces structural damping, reducing the signal produced. Additionally, despite the high cost of materials and processing, contemporary processes only produce a 10% yield. This article demonstrates a UME fabrication process with a 60% yield as well as improved amplitude (250% increase) and sensitivity (210% increase) during SF imaging. This process is expected to improve the signal to noise ratio of SF-based measurement systems. With these improvements, SECM-SF could become a more suitable technique for measuring cell or tissue activity, corrosion of materials, or coupled mechanics of synthetic faradaic materials.
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Mostafa, Tarek M., Moutazbellah Khater, Mehmet Ozakin, Guang Ooi, Hakan Bagci, and Shehab Ahmed. "A Transmitter-Less Inspection Tool for Pipe Defect Detection and Characterization." In SPE Annual Technical Conference and Exhibition. SPE, 2022. http://dx.doi.org/10.2118/210331-ms.
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Abstract Pipe strings are commonly employed in the oil and gas sector, where they are subjected to immense strains and highly corrosive fluids. Electromagnetic (EM) based inspection tools are widely used and typically require one or more excitation sources (i.e., transmitter coil(s)), as well as sensing devices, which adds complexity and expense. By utilizing the inductive sensing principle, this work introduces a novel inspection method with no transmitter coil(s) capable of characterizing inner and full metal loss on the pipe's body. The proposed technique has been modeled and simulated using the commercial EM solver ANSYS Maxwell, as well as a proof of concept prototype, has been built. The results reveal that the tool could detect full and partial metal loss and fully characterize the defect's size, location, and depth.
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Roy, Ting, Kamel Ben Naceur, Manjinder Singh, Daniel Markel, Leonard Harp, Hifzi Ardic, Christian Wilkinson, and Indranil Roy. "Pioneering Oil-Degradable Nano-Composites for Deepwater Sand-Control Tools: To Preclude Annular-To-Tubular Communication During Deployment in Brine, and Degradation-To-Removal in Oil, Ensuing Production." In SPE Annual Technical Conference and Exhibition. SPE, 2022. http://dx.doi.org/10.2118/210130-ms.
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Abstract In the energy industry many applications and embodiments are envisioned, for temporary sealing to dissolvables where deployed tools may remove themselves without any intervention, and on demand. Triggers for dissolution are often common downhole fluids of an aqueous nature. Metals designed to undergo accelerated corrosion via anodic dissolution or hydrolysable polymers triggered by brackish water, flowback or produced, facilitated by elevated downhole temperatures, are common. However, there is not a single formulation with tailored properties, engineered to degrade in presence of oil. Here we present, industry's first oil degradable, nano-composite formulations, for HPHT temporary sealing. An application, as a one-way port plug or ball valve for deploying a sand screen using this novel technology will be ideal. The ball would seal against the flow-ports or nozzles when running in hole and circulating fluid through the screen to the toe and back up the annulus. Once the screens are set, and the well put on production, the oil will produce through the flow ports or nozzles, better known as inflow control devices or ICDs’ and drive the ball away. The ball is to be retained in a cage to allow unrestricted production. In reality, this solution however presents challenges. Production of solids, waxes and asphaltenes often gum up the ball in the cage and restrict production, often needing costly intervention. The ideal scenario will be if the ball seals can dissolve in produced hydrocarbons aka oil of varying API gravities. This will ensure unrestricted production, reduce possibility of intervention and rig time savings, all in all a step towards lowering our carbon footprint. To augment the patented answer product, a step change in adding sensing and intelligence, nano-particulates and/or sensors as unique-identifiers are accommodated in the composite bulk, as tracers, control-released during degradation. As these nano-particulates, flow-back with production to the surface, these tracers with a unique fingerprint, are identified as they pass-through an in-line detector identifying the nano-crystal. The detector, comprising a remote computing system configured to store and relay information relating to these tracers is under development. This industry first is a paradigm shift in remote-monitoring, alerting any end user, anywhere in the world, of selected downhole event triggers, without running any device in the well.
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Fawzy, Ahmed Mohamed, Noor Nazri Talib, Ruslan Makhiyanov, Arslan Naseem, Nestor Molero, Rao Shafin Khan, Philippe Enkababian, Wafaa Belkadi, Ahmed ElAttar, and Amer Ibrahim. "Single-Phase Retarded Inorganic Acid Optimizes Remediation of Drilling Formation Damage in High-Temperature Openhole Horizontal Carbonate Producer." In Abu Dhabi International Petroleum Exhibition & Conference. SPE, 2021. http://dx.doi.org/10.2118/208185-ms.
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Abstract In high-temperature carbonate producers, conventional hydrochloric (HCl) acid systems have been ineffective at delivering sustainable production improvement due to their kinetics. Retarded acids are deemed necessary to control the reaction and create effective wormholes. This scenario is even more critical in wells completed across long openhole horizontal intervals due to reservoir heterogeneity, changing downhole dynamics, and uniform acid placement goals. Out of the different retarded acid options, emulsified acid is one of the preferred choices by Middle East operators because of its excellent corrosion inhibition and deep wormhole penetration properties. However, it also brings other operational complexities, such as higher friction pressures, reduced pump rates, and more elaborate mixing procedures, which in some cases restrict its applicability. The recent introduction of a single-phase retarded inorganic acid system (SPRIAS) has enabled stimulation with the same benefits as emulsified acids while eliminating its drawbacks, allowing friction pressures like that of straight HCl and wormholing performance equivalent to that of emulsified acid. A newly drilled oil producer in one of the largest carbonate fields in onshore Middle East was selected by the operator for pilot implementation of the SPRIAS as an alternative to emulsified acid. The candidate well featured significant damage associated with drilling, severely affecting its productivity. The well was completed across 3,067 ft of 6-in. openhole horizontal section, with a bottomhole temperature of 285°F, permeability range of 0.5 to 1.0 md, and an average porosity of 15%. Coiled tubing (CT) equipped with fiber optics was selected as the fluid conveyance method due to its capacity to enable visualization of the original fluid coverage through distributed temperature sensing (DTS), thus allowing informed adjustment of the stimulation schedule as well as identification of chemical diversion and complementary fluid placement requirements. Likewise, lower CT friction pressures from SPRIAS enabled the utilization of high-pressure jetting nozzle for enhanced acid placement, which was nearly impossible with emulsified acid. Following the acidizing treatment, post-stimulation DTS showed a more uniform intake profile across the uncased section; during well testing operations, the oil production doubled, exceeding the initial expectations. The SPRIAS allowed a 40% reduction in CT friction pressures compared to emulsified acid, 20% optimization in stimulation fluids volume, and reduced mixing time by 18 hours. The experience gained with this pilot well confirmed the SPRIAS as a reliable option to replace emulsified acids in the region. In addition to production enhancement, this novel fluid simplified logistics by eliminating diesel transportation, thus reducing equipment and environmental footprints. It also reduces friction, thus enabling high-pressure jetting via CT, leading to more efficient stimulation with lower volumes.
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Saidi, Kamel S., Jongwon Seo, S. V. Sreenivasan, Carl T. Haas, and Alfred E. Traver. "Design of a Tele-Robotic System for the Maintenance of Boiler Hoppers in Electric Power Plants." In ASME 1998 Design Engineering Technical Conferences. American Society of Mechanical Engineers, 1998. http://dx.doi.org/10.1115/detc98/mech-5998.
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Abstract The design of a novel tele-operated robotic device for clearing undesirable residues (known as clinkers) from the bottom of boiler hoppers in electric power plants is presented in this article. A key aspect of the problem that drives the design process is the fact that the environment inside the hopper is harsh and unstructured. The part of the device that goes into the boiler through a hatch door must be able to handle high temperatures, highly corrosive ash, and the possibility of large residues falling on the device which could lead to serious structural damage to the device. This has led to a new robot design which has all its sophisticated mechanical and control hardware located outside the boiler hopper access port. The only component that goes into the boiler is an inexpensive pole which is expendable and easily replaceable. Also, it can be pulled out from the hopper even if it is seriously damaged. A special insertion mechanism serves as a prismatic joint for inserting and extracting the pole. Forward (sensing) and inverse (control) kinematics problems that are unique to this new design are also presented. Finally, a discussion of the results from preliminary experimental testing in a laboratory setting is included. An important component of the process of designing the robot was the inclusion of ideas from the currently practiced manual clinker clearing process. This was accomplished via periodic discussions with the plant workers who perform the manual process.