Flexible and adaptable hybrid sensor for HTHA detection

Patent metadata

Field	Value
Publication number	US-12130256-B2
Application number	US-202217715392-A
Country	US
Kind code	B2
Filing date	Apr 7, 2022
Priority date	Apr 7, 2022
Publication date	Oct 29, 2024
Grant date	Oct 29, 2024

Abstract

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.

First claim

What is claimed is:

1. A computer-implemented method, comprising:
installing, using at least one drone configured with an extended arm, removable sensors at first locations on base metal of equipment used in hydrocarbon facilities, wherein the first locations comprise locations that are identified as being susceptible to formation of microcracks due to high temperature hydrogen attack (HTHA) based on a history of the equipment, and wherein the removable sensors are attached to the equipment at elevated heights on the equipment using adaptable hybrid pads, the removable sensors detecting the microcracks by adhesion force based on a high-temperature suction substrate adhering up to a set temperature during an inspection processes;
capturing, using the removable sensors and as captured surface data, surface data comprising surface temperatures, per hydrogen (pH) measurements, and methane measurements for methane escaping from external surfaces of the equipment;
determining, using the captured surface data, a presence of the microcracks in the base metal;
performing an HTHA susceptibility analysis of the equipment based, at least in part, on the presence of the microcracks and by analyzing the captured surface data;
mapping, based at least on the HTHA susceptibility analysis, potential HTHA microcracks and first methane formation locations presenting early signs of methane formation;
installing, using the at least one drone configured with the extended arm, the removable sensors at second locations on the base metal of equipment used in hydrocarbon facilities, wherein the second locations comprise locations that are identified as being susceptible to formation of the microcracks due to the HTHA based on a history of the equipment;
capturing, using the removable sensors and as the captured surface data, the surface data comprising the pH measurements, and the methane measurements for the methane escaping from external surfaces of the equipment;
determining, using the captured surface data, the presence of the microcracks in the base metal;
performing microcracks HTHA susceptibility analysis of the equipment based, at least in part, on the presence of the microcracks and by analyzing the captured surface data;
mapping, based at least on the HTHA susceptibility analysis, potential HTHA microcracks and second methane formation locations; and
generating, using the captured surface data, an inspection result and a suggestion, the inspection result comprising a final analysis of assessment reports indicating a likelihood of microcracks propagation and a presence of fissuring inside the base metal and the suggestion comprising a modification of an operation of the equipment to prevent risks indicated by the inspection result.

2. The computer-implemented method of claim 1 , wherein the removable sensors comprise a pulsed eddy current (PEC) array.

3. The computer-implemented method of claim 1 , wherein the removable sensors comprise high-temperature suction skins including suction cups.

4. The computer-implemented method of claim 1 , wherein capturing the surface data comprises using wireless communications of the surface data from the removable sensors to an onsite computer system.

5. The computer-implemented method of claim 1 , wherein the first locations and second locations are selected using field inspection and engineers.

6. The computer-implemented method of claim 1 , wherein capturing the surface data comprises recording, with the surface data for each removable sensor, a location on the equipment on which the removable sensor is installed.

7. The computer-implemented method of claim 1 , further comprising:
determining, based at least on an equipment history of the equipment, that the first locations comprise locations that are susceptible to HTHA.

8. A non-transitory, computer-readable medium storing one or more instructions executable by a computer system to perform operations comprising:
installing, using at least one drone configured with an extended arm, removable sensors at first locations on base metal of equipment used in hydrocarbon facilities, wherein the first locations comprise locations that are identified as being susceptible to formation of microcracks due to high temperature hydrogen attack (HTHA) based on a history of the equipment, and wherein the removable sensors are attached to the equipment at elevated heights on the equipment using adaptable hybrid pads, the removable sensors detecting the microcracks by adhesion force based on a high-temperature suction substrate adhering up to a set temperature during an inspection processes;
capturing, using the removable sensors and as captured surface data, surface data comprising surface temperatures, per hydrogen (pH) measurements, and methane measurements for methane escaping from external surfaces of the equipment;
determining, using the captured surface data, a presence of the microcracks in the base metal;
performing an HTHA susceptibility analysis of the equipment based, at least in part, on the presence of the microcracks and by analyzing the captured surface data;
mapping, based at least on the HTHA susceptibility analysis, potential HTHA microcracks and first methane formation locations presenting early signs of methane formation;
installing, using the at least one drone configured with the extended arm, the removable sensors at second locations on the base metal of equipment used in hydrocarbon facilities, wherein the second locations comprise locations that are identified as being susceptible to formation of the microcracks due to the HTHA based on a history of the equipment;
capturing, using the removable sensors and as the captured surface data, the surface data comprising the pH measurements, and the methane measurements for the methane escaping from external surfaces of the equipment;
determining, using the captured surface data, the presence of the microcracks in the base metal;
performing microcracks HTHA susceptibility analysis of the equipment based, at least in part, on the presence of the microcracks and by analyzing the captured surface data;
mapping, based at least on the HTHA susceptibility analysis, potential HTHA microcracks and second methane formation locations; and
generating, using the captured surface data, an inspection result and a suggestion, the inspection result comprising a final analysis of assessment reports indicating a likelihood of microcracks propagation and a presence of fissuring inside the base metal and the suggestion comprising a modification of an operation of the equipment to prevent risks indicated by the inspection result.

9. The non-transitory, computer-readable medium of claim 8 , wherein the removable sensors comprise a pulsed eddy current (PEC) array.

10. The non-transitory, computer-readable medium of claim 8 , wherein the removable sensors comprise high-temperature suction skins including suction cups.

11. The non-transitory, computer-readable medium of claim 8 , wherein capturing the surface data comprises using wireless communications of the surface data from the removable sensors to an onsite computer system.

12. The non-transitory, computer-readable medium of claim 8 , wherein the first locations and second locations are selected using field inspection and engineers.

13. The non-transitory, computer-readable medium of claim 8 , wherein capturing the surface data comprises recording, with the surface data for each removable sensor, a location on the equipment on which the removable sensor is installed.

14. The non-transitory, computer-readable medium of claim 8 , the operations further comprising:
deter

Assignees

• Saudi Arabian Oil Co

Inventors

• Amer Ayman
• Halawani Abdulwahab A

Classifications

• G01N27/904

  with two or more sensors · CPC title

• G01N27/9073

  Recording measured data · CPC title

• G01N27/9006 Primary

  Details, e.g. in the structure or functioning of sensors · CPC title

• G01N27/902 Primary

  by moving the sensors · CPC title