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DOE OSTI2023

Analysis of WIRE-21 SPND and Optical Fiber Sensor Measurements

The Wireless Instrumented RB Experiment 2021 (WIRE-21) was a highly instrumented experiment designed to test prototype wireless temperature and pressure sensors developed by Westinghouse Electric Corporation (WEC) in the High Flux Isotope Reactor (HFIR). In addition to these sensors, a suite of other sensors was also integrated into the experiment capsule, including various types of distributed optical fiber sensors and self-powered neutron detectors (SPNDs). This report presents an analysis of the data generated by the SPNDs and optical fiber sensors that were tested under the highest reported neutron flux. The distributed optical fiber sensor results demonstrate that F-doped optical fibers, particularly those inscribed with fs fiber Bragg gratings (FBGs), are capable of surviving fast neutron fluences on the order of 1021 n fast /cm 2 at temperatures relevant to light-water reactors (between 200 and 400°C). However, a significant blue-shift in the optical spectra of these sensors was observed over the course of irradiation which cannot be explained based on the current understanding of radiation-induced compaction in fused silica glass. A mechanistic understanding of this drift has not yet been developed and is proposed as future scope under the Advanced Sensors and Instrumentation program. Of the four SPNDs, only one appeared to operate normally during three cycles of irradiation. A radiation transport model of the experiment in HFIR was used to determine time-dependent neutron flux in this SPND and to calculate the neutron sensitivity of the device. Results showed a cycle averaged sensitivity of 1.5 ×10 -22 and 1.4 ×10 -22 A/nν for the first and third cycles of irradiation, respectively. Additional details pertaining to the optical fibers and SPNDs are included herein.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Optical Fiber Sensor Technology Development and Field Validation for Distribution Transformer and Other Grid Asset Health Monitoring

Power transformers are critical pieces of infrastructure in the electric grid that are both extremely expensive and difficult to replace. These transformers often have long lead times for replacement, and failures can create long service disruptions. This project has developed a new suite of sensors designed to give early warning of the impending failure of these important power transformers before it is too late and a major failure occurs. By using novel fiber optic sensors instead of conventional existing technologies, we are able to measure transformer characteristics indicative of impending failures in ways that were not previously possible. These new optical fiber-based sensors are completely immune to the strong magnetic fields present in power transformers, as well as being capable of using distributed measurement techniques. Distributed measurement techniques enable the fiber to return information all along its length as opposed to only collecting data at a single point; as would a thermocouple or standard pressure sensor.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Method of making a distributed optical fiber sensor having enhanced Rayleigh scattering and enhanced temperature stability, and monitoring systems employing same

A method of making an optical fiber sensor device for distributed sensing includes generating a laser beam comprising a plurality of ultrafast pulses, and focusing the laser beam into a core of an optical fiber to form a nanograting structure within the core, wherein the nanograting structure includes a plurality of spaced nanograting elements each extending substantially parallel to a longitudinal axis of optical fiber. Also, an optical fiber sensor device for distributed sensing includes an optical fiber having a longitudinal axis, a core, and a nanograting structure within the core, wherein the nanograting structure includes a plurality of spaced nanograting elements each extending substantially parallel to the longitudinal axis of the optical fiber. Also, a distributed sensing method and system and an energy production system that employs such an optical fiber sensor device.

42 ENGINEERING↗

DOE OSTI2022

Method of making a distributed optical fiber sensor having enhanced Rayleigh scattering and enhanced temperature stability, and monitoring systems employing same

Chen, Peng Kevin↗

DOE OSTI2021

Optical monitoring to detect contamination of power grid components

A monitoring system includes an array of optical sensors disposed within a transformer tank. Each optical sensor is configured to have an optical output that changes in response to a temperature within the transformer tank. An analyzer is coupled to the array of optical sensors. The analyzer is configured to determine a sensed temperature distribution based on the sensed temperature. The sensed temperature distribution is compared to an expected distribution. Exterior contamination of the transformer tank is detected based on the comparison.

Mostafavi, Saman↗

DOE OSTI2023

Optical monitoring to detect contamination of power grid components

Mostafavi, Saman↗

DOE OSTI2024

Achieving precise multiparameter measurements with distributed optical fiber sensor using wavelength diversity and deep neural networks

The development of advanced distributed optical fiber sensing systems that are capable of performing accurate and spatially resolved multiparameter measurements is of great interest to a wide range of scientific and industrial applications. Here, in this paper, we propose and experimentally demonstrate a wavelength diversity based advanced distributed optical fiber sensor system to accomplish multiparameter sensing while greatly enhancing measurement accuracy. A suite of deep neural network (DNN) algorithms are developed and verified for data denoising, rapid Brillouin frequency shift estimation, and vibration data event classification. As a proof-of-concept, we demonstrate the effectiveness of the proposed advanced wavelength diversity distributed fiber sensor system assisted by DNN for simultaneous, independent measurements of static strain, temperature, and acoustic vibrations over a 25 km long sensing fiber at 3 m spatial resolution. These results suggest the potential for an intelligent multiparameter monitoring system with enhanced performance in advanced structural health monitoring applications.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Application of Distributed Fiber Optic Strain Sensors to LMQXFA Cold Mass Welding

The future High Luminosity upgrade of the Large Hadron Collider (HL-LHC) at CERN will include the low-beta inner triplets (Q1, Q2a/b, Q3) for two LHC insertion regions. The Q1, Q3 components consist of eight 10 m-long LMQXFA cryo-assemblies fabricated by the HL-LHC Accelerator Upgrade Project. Each LMQXFA Cold mass contains two Nb 3 Sn magnets connected in series. A stainless-steel shell is welded around the two magnets before the insertion into the cryostat. There is a limit on how much coil preload increase induced by the shell welding is allowed. Distributed Rayleigh backscattering fiber optics sensors were used for the first time to obtain a strain map over a wide area of a Nb 3 Sn magnet cold mass shell. Finally, data were collected during welding of the first LMQXFA cold mass and the results confirm that the increase of the coil pole azimuthal pre-stress after welding do not exceed requirements.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Integrated quantum optical phase sensor in thin film lithium niobate

Abstract The quantum noise of light, attributed to the random arrival time of photons from a coherent light source, fundamentally limits optical phase sensors. An engineered source of squeezed states suppresses this noise and allows phase detection sensitivity beyond the quantum noise limit (QNL). We need ways to use quantum light within deployable quantum sensors. Here we present a photonic integrated circuit in thin-film lithium niobate that meets these requirements. We use the second-order nonlinearity to produce a squeezed state at the same frequency as the pump light and realize circuit control and sensing with electro-optics. Using 26.2 milliwatts of optical power, we measure (2.7 ± 0.2)% squeezing and apply it to increase the signal-to-noise ratio of phase measurement. We anticipate that photonic systems like this, which operate with low power and integrate all of the needed functionality on a single die, will open new opportunities for quantum optical sensing.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Fiber Optic Temperature Sensor System Using Air-Filled Fabry–Pérot Cavity with Variable Pressure

We report a high-resolution fiber optic temperature sensor system based on an air-filled Fabry–Pérot (FP) cavity, whose spectral fringes shift due to a precise pressure variation in the cavity. The absolute temperature can be deduced from the spectral shift and the pressure variation. For fabrication, a fused-silica tube is spliced with a single-mode fiber at one end and a side-hole fiber at the other to form the FP cavity. The pressure in the cavity can be changed by passing air through the side-hole fiber, causing the spectral shift. We analyzed the effect of sensor wavelength resolution and pressure fluctuation on the temperature measurement resolution. A computer-controlled pressure system and sensor interrogation system were developed with miniaturized instruments for the system operation. Experimental results show that the sensor had a high wavelength resolution (<0.2 pm) with minimal pressure fluctuation (~0.015 kPa), resulting in high-resolution (±0.32 ℃) temperature measurement. It shows good stability from the thermal cycle testing with the maximum testing temperature reaching 800 ℃.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Soil water content, matric potential, carbon dioxide and oxygen concentrations, Oct 2018-Dec 2021, Slate River Floodplain, Crested Butte, Colorado

This data package includes a time series of soil sensor data (temperature, water content, bulk electrical conductivity, porewater dissolved oxygen and porewater dissolved carbon dioxide) in a vertical profile from the Slate River floodplain outside Crested Butte, Colorado, a focus field site for the SLAC Floodplain Hydro-Biogeochemistry SFA. The data was generated as part of the work targeting the overarching research question for the SLAC SFA: How do ubiquitous subsurface interfaces mediate molecular-scale biogeochemical processes and groundwater quality in floodplains and watersheds? The package includes: (1) soil temperature, volumetric water content and electrical conductivity at 40, 60 and 82.5 cm depth; (2) soil matric potential at 40, 60, 79 and 100 cm depth; (3) soil CO2 concentrations at 40, 60 and 82.5 cm depth; and (4) soil oxygen concentrations at 60, 82.5, 100, 135, 170 and 182 cm depth. Both the carbon dioxide and oxygen sensors are optical sensors that can measure the partial pressure of oxygen in both saturated and unsaturated conditions. Unfortunately, soil CO2 in the profile is unexpectedly high and above the sensor calibration range (0-25,000 ppm). In addition, soil CO2 sensors failed within a year of deployment, so we only report CO2 data from 2019-2020.Within the data package, "FLMD.csv" describes file-level metadata and "dd.csv" defines column headers and universal terms across the dataset. The data package includes 4 "*data.csv" files, one for each calendar year in the dataset. Each "*data.csv" file has a corresponding "*_InstallationMethods.csv" file that describes the location, sensor model, sensor serial number and other metadata corresponding for each measured parameter. Because sensors have been added over time, not every sensor has data dating back to Oct 2018. Note that there is a data gap over winter 2019-2020 due to a power outage. While this repository currently only contains data through December 2021, the dataset will be updated as additional years are collected and processed.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Multi-channel optical detection system and method for multi-chamber assays

A multi-channel optical detection system includes a base unit adapted to receive a multi-chamber assay cartridge having a plurality of reaction chambers loaded with a sample and an optical detection reagent, and an optical detection unit having a multi-channel optical block having a plurality of detection channels each with an associated light source, and an optic sensor. The optical detection unit is connectable to the base unit so that interrogation ports of the detection channels are optically aligned with optically transparent windows of the reaction chambers of a loaded cartridge, so that upon initialization, light sources are activated to interrogate reaction products in the reaction chambers and detect the optical responses therefrom.

Dugan, Lawrence C.↗

DOE OSTI2023

Structural analysis of molten materials by a remote fiber optic Raman sensor

This study presents a novel in situ high-temperature fiber optic Raman probe that enables the study of the physical properties and structure of molten samples at temperatures up to 1400 °C. To demonstrate the functionality of the high-temperature fiber optic Raman probe, different composition mold fluxes were evaluated in this report. The Raman spectra at flux molten temperature were successfully collected and analyzed. A deconvolution algorithm was employed to identify peaks in the spectra associated with the molecular structure of the components in each sample. Here, the experimental results demonstrate that the composition-dependent Raman signal shift can be detected at high temperatures, indicating that molten materials analysis using a high-temperature Raman system shows significant promise. This flexible and reliable high-temperature Raman measurement method has great potential for various applications, such as materials development, composition and structure monitoring during high-temperature processing, chemical identification, and process monitoring in industrial production.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Method and system to separate optically measured coupled parameters

A system includes a first optical sensor sensitive to both a parameter of interest, Parameter1, and at least one confounding parameter, Parameter2 and a second optical sensor sensitive only to the confounding parameter. Measurement circuitry measures M1 in response to light scattered by the first optical sensor, where M1=value of Parameter1+K*value of Parameter2. The measurement circuitry also measures M2 in response to light scattered by the second optical sensor, where M2=value of Parameter2. Compensation circuitry determines a compensation factor, K, for the confounding parameter based on measurements of M1 and M2 taken over multiple load/unload cycles or over one or more thermal cycles. The compensation factor is used to determine the parameter of interest.

Ganguli, Anurag↗

DOE OSTI2022

Gas sensor including optic fiber connector

A gas detector sensor node includes a first sensor conductor having a terminal end, a second sensor conductor including an end section, and a coupler joining the terminal end of the first sensor conductor with the end section of the second sensor conductor. The coupler is permeable to gas.

Karp, Jason Harris↗

DOE OSTI2023

Advancing Aluminum Casting Optimization With Real-Time Temperature and Gap Measurements Using Optical Fiber Sensors at the Metal-Mold Interface

Not Available

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗