Development of Erosion Sensors for Internal Pipeline Coatings

罗森加拿大有限公司在泥浆管道内涂层领域提供高价值的工程服务。他们提供内部管道涂料，这种涂料是以聚氨酯为基础的聚合物涂料，其组成专门用于抵抗油砂引起的内部冲刷和腐蚀。厚厚的一层涂层可以保护钢管平均4到6个月的时间，然后才能使管道“翻转”。在这一过程中，磨损最严重的底部部分移动到磨损较少的侧壁或顶部，取而代之的是涂层较少磨损的部分。经过反复的涂层循环后，涂层必须更换为新的涂层。然而，罗森加拿大公司面临的具体挑战是，他们缺乏一种直接监测管道涂层冲蚀磨损的方法。传统的在线检测(ILI)工具经常对上游管道提出挑战，由于ILI工具的使用导致管道服务中断，因此不能频繁地部署，从外部间接测量或基于经验的冲蚀率估计是常见的做法，这导致更频繁的转弯和更换，增加了管道运行的成本和时间损失。随着人们对管道完整性管理的日益关注，对管道内涂层进行直接、连续监测的重要性日益凸显，本课题的主要目标是研制管道内涂层的腐蚀传感器。传感器必须准确，提供连续的数据测量，坚固耐用，并完全集成到涂层本身。为了实现这一目标，卡尔加里大学和加拿大罗森大学建立了合作关系，提出了用于磨损检测目的的导电聚合物纳米复合材料传感器。本项目将进行基于纳米复合材料的腐蚀传感器的原型设计、制造、测试、表征和优化。鉴于管道行业对于能源部门对加拿大经济的重要性，新的腐蚀传感器将为该行业和国家带来重大好处。

ROSEN Canada Ltd. provides high-value engineering services in the field of pipeline internal coating for slurrypipes. They provides internal pipeline coating which is polyurethane based polymer coating, where itscomposition is specialized to resist wear due to internal erosion and corrosion caused by oil sands. The thicklayer of coating protects the steel pipelines for the average of 4 to 6 months before they 'turn' the pipes. In thisprocess, the most worn out bottom section moves to the less wear-intensive sidewalls or the top, replaced byless worn out section of the coating. After repeating cycle of the coating turns, the coating has to be replaced bya fresh new coating layer.The specific challenge for ROSEN Canada, however, is that they lack a direct method to monitor the erosionwear of pipeline coatings. The upstream pipelines are often challenging to the traditional Inline Inspection (ILI)tools, and they cannot be deployed frequently as the use of ILI causes disruption in the pipeline services.Indirect measurements from outside or experience based erosion rate estimation are common practices whichled to more frequent 'turn' and replacement, increasing the cost and time loss in pipeline operation. With theincreasing concern over pipeline integrity management, the importance of direct and continuous monitoring ofinternal pipeline coating has become more significant.The main goal of this project is to develop erosion sensors of the pipeline internal coating. The sensor must beaccurate, providing continuous measurement of the data, robust and fully integrated into the coating itself. Toachieve this goal, the University of Calgary and ROSEN Canada have formed a collaborative relationship,proposing electrically conductive polymer nanocomposites sensors for wear detection purposes. Prototypedesign, fabrication, testing, characterization and optimization of nanocomposite-based erosion sensors will beperformed in this project. Given the importance of the pipeline industry for the energy sector to the Canadianeconomy, the new erosion sensor will provide a significant benefit to the industry and the nation.