This paper addresses the design and development of a fiber-optic monitoring system that can be deployed on existing deep water risers and flow lines; and provides a summary of test article fabrication and the subsequent laboratory testing performed at the National Aeronautics and Space Administration-Johnson Space Center (NASA-JSC). A major challenge of a post-installed instrumentation system is to ensure adequate coupling between the instruments and the riser or flow line of interest. This work investigates the sensor coupling for pipelines that are suspended in a water column (from topside platform to seabed) using a fiber-optic sensor clamp and subsea bonding adhesive. The study involved the design, fabrication, and test of several prototype clamps that contained fiber-optic sensors. A mold was produced by NASA using 3-D printing methods that allowed the casting of polyurethane clamp test articles to accommodate 4-inch and 8-inch diameter pipes. The prototype clamps were installed with a subsea adhesive in a “wet” environment and then tested in the NASA Structures Test Laboratory (STL). The tension, compression, and bending test data showed that the prototype sensor clamps achieved good structural coupling, and could provide high quality strain measurement for active monitoring.
This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system capable of measuring pressure, strain, and temperature that can be deployed on existing subsea structures. A summary is provided of the design concept, prototype development, prototype performance testing, and subsequent design refinements of the device. The results of laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are also included. Limitations of the initial concept were identified during testing and future design improvements were proposed and later implemented. These new features enhance the coupling of the sensor device and improve the monitoring system measurement capabilities.A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on flowlines, risers, and other subsea structures. The work described in this paper investigates the design and test of a friction-based coupling device (herein referred to as a friction clamp) which is suitable for pipelines and structures that are suspended in the water column as well as for those that are resting on the seabed. The monitoring elements consist of fiberoptic sensors that are bonded to a stainless steel clamshell assembly with a high-friction surface coating. The friction clamp incorporates a single hinge design to facilitate installation of the clamp and dual rows of opposing fasteners to distribute the clamping force along the structure. The friction clamp can be modified to be installed by commercial divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system.
A monitoring system that can be deployed on already existing deepwater risers and flowlines has been developed. This paper describes the design concepts and testing that was performed in developing the monitoring system. A major challenge of a post-installed instrumentation system is to ensure adequate coupling is achieved between the instruments and the riser or flowline. This work investigates the sensor coupling for pipelines that are suspended in both the water column (from topside platform to the seabed) and for those that are located directly on the seabed. These different environments necessitate two sensor attachment methods: (1) sensor clamp design with subsea adhesive and (2) sensor clamp design with friction surface coating. This paper addresses the adhesive attachment method. The monitoring elements consist of fiber optic sensors that are encased in a polyurethane clamp. With a subsea adhesive, the clamp can be installed by divers in shallow depths or by use of an ROV for deeper applications. The NASA Johnson Space Center was initially involved in the selection and testing of subsea adhesives. It was determined that up to 75 percent of the bonding strength could be achieved with the adhesive from optimal dry bonding versus bonding in submerged sea water environments. The next phase of the study involved the design, fabrication, and testing of several prototype clamps that incorporated the fiber optic sensors. Several molds were produced by NASA using 3-D printing that allowed the fabrication of subscale test articles that would accommodate 4-inch and 8-inch diameter pipes. The clamps were installed with adhesive in a "wet" environment on the pipe test articles and evaluated in the NASA Structures Test Laboratory. The tension/compression and bending tests showed that the prototype sensor clamps achieved good coupling, and could provide high quality strain measurement for active monitoring.
This paper continues to document the design, development, and test of a friction-based (non-adhesive) post-installable fiber-optic strain sensing system for oil and gas applications — especially those that require deployment on existing subsea structures. (Ref: OMAE2017-61494 Development and Testing of a Friction-Based Post-Installable Sensor for Subsea Fiber-Optic Monitoring Systems [1]). The prototype fiber-optic monitoring system collects a wide range of real-time data, which can be used to determine structural loading, fatigue, temperature, pressure, and flow assurance on operational platforms. The primary challenge of a post-installed instrumentation monitoring system is to ensure secure coupling between the sensors and the structure of interest for reliable measurements. Friction-based coupling devices have the potential to overcome installation challenges caused by marine growth and soil contamination on subsea structures, flowlines, or risers. This particular design solution is compatible with structures that are suspended in the water column and those that are resting on the seabed. In addition, the system can be installed by commercial divers in shallow depths or by remotely operated vehicles in deep-water applications. Operational limitations of the initial design concept were identified in the previous series of tests (2016–2017), and several innovative enhancements have been implemented which resulted in significant improvements in sensor system coupling and strain measurement correlation with traditional strain measuring devices. This paper provides a summary of the notable prototype design changes, full-scale test article buildup, and detailed performance data recorded during tension and compression loading that simulated representative offshore conditions. The test results were positive and demonstrated the effectiveness of the design enhancements. Compromises made during mounting of the sensing elements resulted in better performance in tension than compression. These effects are well understood and are fully discussed, and do not influence the viability of the design changes. This study is part of a continuing collaboration between the Houston-based NASA-Johnson Space Center and Astro Technology, Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance these technologies that would benefit the environment, the public, and commercial industries.
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