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NASA NTRS2007

Optical Fiber Distributed Sensing Structural Health Monitoring (SHM) Strain Measurements Taken During Cryotank Y-Joint Test Article Load Cycling at Liquid Helium Temperatures

This paper outlines cryogenic Y-joint testing at Langley Research Center (LaRC) to validate the performance of optical fiber Bragg grating strain sensors for measuring strain at liquid helium temperature (-240 C). This testing also verified survivability of fiber sensors after experiencing 10 thermal cool-down, warm-up cycles and 400 limit load cycles. Graphite composite skins bonded to a honeycomb substrate in a sandwich configuration comprised the Y-joint specimens. To enable SHM of composite cryotanks for consideration to future spacecraft, a light-weight, durable monitoring technology is needed. The fiber optic distributed Bragg grating strain sensing system developed at LaRC is a viable substitute for conventional strain gauges which are not practical for SHM. This distributed sensing technology uses an Optical Frequency Domain Reflectometer (OFDR). This measurement approach has the advantage that it can measure hundreds of Bragg grating sensors per fiber and the sensors are all written at one frequency, greatly simplifying fiber manufacturing. Fiber optic strain measurements compared well to conventional strain gauge measurements obtained during these tests. These results demonstrated a high potential for a successful implementation of a SHM system incorporating LaRC's fiber optic sensing system on the composite cryotank and other future cryogenic applications.

Allison, Sidney G.↗

DOE OSTI2026

Embedding Fiber Optic Sensors in Stainless Steel using Spark Plasma Sintering for Structural Health Monitoring in Harsh Environments

Embedded fiber optic sensors such as fiber Bragg gratings (FBGs) offer a unique route for distributed real-time in-situ imaging of various engineering parameters for numerous purposes. This study advanced the current sensor embedding approaches by exploring a spark plasma sintering (SPS)-assisted technology to embed FBGs in high-temperature structural materials and demonstrated the capability of temperature measurement. In this approach, single-mode FBGs were integrated into stainless steel (SS) 316L components using SPS, followed by the evaluation of the bonding quality between the FBGs and matrix, the optical attenuation of the fibers induced by embedding, and the sensing characters of the FBGs under temperature stimuli. The results demonstrated that superior bonding was achieved between the FBGs and highly-densified SS316L. Examination of the behavior of Bragg gratings validated signal fidelity after embedding. Real-time thermal imaging under temperature cycling using the FBGs demonstrated the effectiveness of the technique for smart materials manufacturing.

36 - MATERIALS SCIENCE↗

DOE OSTI2024

Minimization of Measurement Uncertainty in Optical Frequency Domain Reflectometry

Optical frequency domain reflectometry (OFDR) is a technique for interrogating optical fiber sensors to generate relative, quasi-distributed measurements. Although Optical frequency domain reflectometry (OFDR) is increasingly being adopted for aerospace, energy production, and structural monitoring applications, the quantification of uncertainty for OFDR measurements has not been developed beyond sparse empirical relationships. To address this knowledge gap, an uncertainty metric for OFDR measurements was developed. This uncertainty metric was applied to weight the edges between OFDR measurements on directed correlation graphs and analyzed to minimize the cumulative uncertainty. In conclusion, this work is the first to propose an uncertainty metric for OFDR and provides a generalized mathematical framework for optimizing OFDR hardware selection, optical fiber sensor selection, and postprocessing strategy.

42 ENGINEERING↗

DOE OSTI2025

Deep Neural Network Assisted Distributed Strain and Temperature Fiber Sensor System for Natural Gas Pipeline Monitoring

Natural gas pipeline integrity monitoring is crucial to detect potential leaks, find structural issues, and prevent environmental damage. This article presents a system of natural gas pipeline monitoring that uses a specialized double Brillouin peak sensing fiber along with the Brillouin optical time domain analysis (BOTDAs) technique. The calibrated sensing fiber coefficients for strain and temperature are 41.8 kHz/ με and 0.9 MHz/°C for peak 1; and 47.2 kHz/ με , and 1.11 MHz/°C for peak 2, respectively. Initially, lab tests were performed by installing a short section of double Brillouin peak fiber (DBPF) on a 1-in steel pipe under pressure up to 1000 per square inch (psi) at elevated temperatures. Simultaneous distributed measurements of temperature and pressure-induced hoop strain were successfully measured. Considering the long processing speed to extract Brillouin frequency shift (BFS), we employ a novel probabilistic deep neural network (PDNN) framework for rapid BFS prediction. Additionally, using the Finite Element Method, the effects of the pipeline pressure on hoop strain were modeled and compared to the experimental hoop strain under the same set of pipeline conditions. Finally, an actual 4-in outer diameter steel natural gas pipeline was used for pilot-scale tests, where hoop strain was measured at various pressure levels. Leaks were simulated to demonstrate accurate pipeline integrity monitoring. At an internal pipe pressure of 1000 psi, hoop strain of approximately 300 με was observed, and the sensitivity was calculated as 0.28 με /psi. The results of this pilot-scale study demonstrated that the system is capable of performing distributed monitoring sufficient to detect pipeline pressure and the presence of leaks to ensure the safe operation of gas pipelines in the field.

03 NATURAL GAS↗

DOE OSTI2023

In-field strain and temperature measurements in a (RE)Ba 2 Cu 3 O 7–x coil via Rayleigh-backscattering interrogated optical fibers

(RE)Ba 2 Cu 3 O 7-x (REBCO) conductors have overcome technical challenges related to manufacturing quality, length homogeneity, scale-up of piece-length, and joints. There is one remaining technical challenge, however, which is common to all high temperature superconductors and lies in effective detection of failure to prevent material degradation. An innovative technique based on optical fibers interrogated by Rayleigh backscattering has been shown to have advantages over voltage taps at detecting incipient faults. Prior work has experimentally demonstrated the technique in several implementation scenarios, including direct integration of optical fibers into superconducting conductors and cables to create a class of ‘SMART’ conductors and cables that are able to monitor their own health. In this paper, the magnet monitoring technique based on Rayleigh backscattering interrogated optical fibers has been experimentally studied in a model coil subject to external magnetic field, where different fiber integration methods are used to increase selectivity of the fiber sensor to temperature. Results show that the spectral shift displays different features during strain and thermal transients. The implications of the results in terms of potential and limitations of each sensor as well as strain-temperature decoupling are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Novel High Resolution High Temperature In-Line Sensors for Steel Manufacturing

To support efficiency, productivity, yield improvements, and future industry 4.0 and SMART manufacturing objectives for a competitive and prosperous steel industry, this program has embarked on an effort to develop, demonstrate and deploy several novel sensing technologies based on fiber optics for use in production steel facilities. Over the duration of this program, our team has successfully demonstrated three of these technologies: (1) near continuous Rayliegh Scattering optical frequency domain reflectometry (OFDR) sensing with single mode silica fibers for temperature sensing to 700 C, (2) semi-distributed fiber Bragg grating (FBG) sensing with multimode sapphire fibers for temperature sensing to >1600 C, and (3) remote in-situ Raman analysis for slag and flux chemistry analysis at steelmaking temperatures >1550 C. Each of these sensor and interrogation systems was developed, refined, and tested in our labs at Missouri S&T and then successfully deployed at SSAB’s production facilities at two sites, one in Montpelier, IA and one in Mobile, AL.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Nickel-incorporated Oxide Composites for Fiber-Optic Based Gas Sensing

Numerous high-value applications within the energy sector involve environmental conditions that are incompatible with traditional sensor technology due to degradation of electrical interconnects, packaging, or the sensors themselves. These can include chemically harsh conditions, high temperature operation, or the presence of electromagnetic interference due to high voltage. The fiber optic platform, constructed of robust, electrically insulating glass or single crystal oxides, offers a versatile and often low cost per node solution to this problem, especially with the integration of distributed sensing techniques such as optical time-domain and frequency-domain reflectometry (OTDR, OFDR). A major challenge of gas and chemical sensing on the optical fiber platform is the fabrication of robust and stable sensing materials that interact quickly and reversibly to the presence of the target analytes. In this work, we discuss the utilization of nickel-incorporated oxides on evanescent-field optical fiber sensors for gas sensing under harsh conditions relevant to multiple energy infrastructure applications. This paper will discuss a Ni/GDC (Ni / Gd-doped ceria) based sensing layer targeting conditions relevant for high-temperature (up to at least 800 oC) hydrogen sensing applications (e.g., for operation within a solid oxide fuel cell or electrolyzer). The impact of hydrogen at elevated temperatures on the optical properties of Ni/GDC will be shown and the material mechanisms for the optical response will be discussed.

gas sensors↗

DOE OSTI2025

Nickel-incorporated Oxide Composites for Fiber-Optic Based Gas Sensing

Numerous high-value applications within the energy sector involve environmental conditions that are incompatible with traditional sensor technology due to degradation of electrical interconnects, packaging, or the sensors themselves. These can include chemically harsh conditions, high temperature operation, or the presence of electromagnetic interference due to high voltage. The fiber optic platform, constructed of robust, electrically insulating glass or single crystal oxides, offers a versatile and often low cost per node solution to this problem, especially with the integration of distributed sensing techniques such as optical time-domain and frequency-domain reflectometry (OTDR, OFDR). A major challenge of gas and chemical sensing on the optical fiber platform is the fabrication of robust and stable sensing materials that interact quickly and reversibly to the presence of the target analytes. In this work, we discuss the utilization of nickel-incorporated oxides on evanescent-field optical fiber sensors for gas sensing under harsh conditions relevant to multiple energy infrastructure applications. This paper will discuss a Ni/GDC (Ni / Gd-doped ceria) based sensing layer targeting conditions relevant for high-temperature (up to at least 800oC) hydrogen sensing applications (e.g., for operation within a solid oxide fuel cell or electrolyzer). The impact of hydrogen at elevated temperatures on the optical properties of Ni/GDC will be shown and the material mechanisms for the optical response will be discussed.

gas sensors↗

DOE OSTI2023

Development of Optical Fiber-Based Sensors for Nuclear Microreactor Structural Health Monitoring

This report provides an experimental assessment of two different optical fiber–based acoustic sensors that are being investigated for application in nuclear microreactors to enhance structural health monitoring capabilities. Optical fibers are resilient in high-temperature and high-radiation environments, have a small sensor footprint, are immune to electromagnetic interference, and are capable of spatially distributed sensing. The two sensors investigated here are (1) Fabry–Pérot Cavities (FPCs) between two copper-coated fibers, embedded in nickel capillary tubes and (2) type-I fiber Bragg grating (FBG) arrays contained within metal capillary tubes. These sensors can be interrogated using low-coherence interferometry or swept wavelength interferometry, respectively, to measure the resonant frequencies of the components or systems to which these sensors are bonded. The FPC developed herein has been subjected to temperatures up to nearly 800°C while tack-welded to a tubular test specimen. Even at the highest temperatures, the measured resonant frequencies compared well with those obtained using an accelerometer that was bonded to an unheated portion of the specimen. The FBG array was tested in multiple bonding configurations to a tubular test specimen, all at room temperature, with the understanding that high temperature (i.e., type II) FBGs could be used to obtain similar data at high temperatures; the FBG array data were validated with noncontact laser vibrometry, which is being used at Los Alamos National Laboratory to relate acoustic signatures to component stresses and/or structural defects. The goal of this work is to identify the most promising techniques that are also compatible with operation in a microreactor environment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

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 OSTI2021

Distributed Fiber Sensors With High Spatial Resolution in Extreme Radiation Environments in Nuclear Reactor Cores

This paper is a comprehensive experimental report on the neutron radiation effects of distributed optical fiber sensors with enhanced Rayleigh scattering profiles in an in-pile environment. Femtosecond laser direct writing was used to inscribe Type-II modifications in standard telecom fibers and radiation-hardened fibers with fluorine-doped cores. Rayleigh backscattering signals were enhanced for continuous 1.5 m. In-pile lead-out sensors tests were carried out at the MIT Research Reactor for two months, which was operated at a nominal power of 5.7 MW with fast neutron (>0.1 MeV) flux of 1.29 × 1014 n/cm2/s and an in-core temperature of up to 560°C. Using the Optical Frequency Domain Reflectometry technique, the backscattering profiles of fiber sensors were interrogated with a 3-cm spatial resolution to monitor the temperature profile of the reactor. Results show that laser inscribed Type-II modifications in the form of nanogratings are highly stable against extreme temperature and ionizing radiation. Both standard telecom fibers and radiation-hardened fibers with laser-enhanced Rayleigh profiles can continuously perform distributed temperature measurements over the entire duration of the in-pile testing. Temperature coefficients of sensors and spectral shift quality were studied as functions of total radiation fluence. To the best of our knowledge, we present for the first time, the temperature profile of an operating nuclear reactor core with 3-cm spatial resolution, enabled by distributed fiber sensors with laser-enhanced Rayleigh scattering profiles. The high spatial resolution measurements can provide valuable data for the design and validation of digital twin and virtual reality of nuclear energy systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Development and Test of a 1,000 Level 3C Fiber Optic Borehole Seismic Receiver Array Applied to Carbon Sequestration

To address the critical site characterization and monitoring needs for CCS programs, US Department of Energy (DOE) awarded Paulsson, Inc. in 2010 a contract to design, build and test a fiber optic based ultra-large bandwidth clamped borehole seismic vector array capable of deploying up to one thousand 3C sensor pods suitable for deployment into high temperature and high pressure boreholes. Paulsson, Inc. has completed a design or a unique borehole seismic system consisting of a novel drill pipe based deployment system that includes a hydraulic clamping mechanism for the sensor pods, a new sensor pod design and most important – a unique fiber optic seismic vector sensor with technical specifications and capabilities that far exceed the state of the art seismic sensor technologies. These novel technologies were all applied to the new borehole seismic system. In combination these technologies will allow for the deployment of up to 1,000 3C sensor pods in vertical, deviated or horizontal wells. Laboratory tests of the fiber optic seismic vector sensors developed during this project have shown that the new borehole seismic sensor technology is capable of generating outstanding high vector fidelity data with extremely large bandwidth: 0.01 – 6,000 Hz. Field tests have shown that the system can record events at magnitudes much smaller than M-2.3 at frequencies up to 2,000 Hz. The sensors have also proved to be about 100 times more sensitive than the regular coil geophones that are used in borehole seismic systems today. The fiber optic seismic sensors have furthermore been qualified to operate at temperatures over 300°C (572°F). The fibers used for the seismic sensors in the system are used to record Distributed Temperature Sensor (DTS) data allowing additional value added data to be recorded simultaneously with the seismic vector sensor data.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Measurement accuracy and spatial resolution of a distributed temperature sensor based on a two-pulse differential coherent reflectometer

We present a model and numerical simulation of a distributed temperature sensor based on a two-pulse differential coherent optical time-domain reflectometer (COTDR). The differential phase measured using a phase-sensitive Rayleigh reflectometer is shown to have a regular component, which is a linear function of temperature, and a random component, which is related to a random distribution of scattering centres in the fibre and restricts the accuracy of measurements of variations in temperature. Measurement accuracy can be improved by reducing the relative contribution of the random component via a decrease in pulse duration and/or an increase in the time delay between pulses. The spatial resolution of a differential two-pulse phase-sensitive reflectometer is shown to be determined by the time delay between pulses and to vary little with pulse duration. At a typical pulse duration (200 ns) and delay time (300 ns), the accuracy in measurements of variations in temperature in the 0.1-K range is 2 % and the spatial resolution is about 30 m. (fibre-optic sensors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2019

Corrosion Sensors for Structural Health Monitoring of Oil and Natural Gas Infrastructure: A Review

Corrosion has been a great concern in the oil and natural gas industry costing billions of dollars annually in the U.S. The ability to monitor corrosion online before structural integrity is compromised can have a significant impact on preventing catastrophic events resulting from corrosion. This article critically reviews conventional corrosion sensors and emerging sensor technologies in terms of sensing principles, sensor designs, advantages, and limitations. Conventional corrosion sensors encompass corrosion coupons, electrical resistance probes, electrochemical sensors, ultrasonic testing sensors, magnetic flux leakage sensors, electromagnetic sensors, and in-line inspection tools. Emerging sensor technologies highlight optical fiber sensors (point, quasi-distributed, distributed) and passive wireless sensors such as passive radio-frequency identification sensors and surface acoustic wave sensors. Emerging sensors show great potential in continuous real-time in-situ monitoring of oil and natural gas infrastructure. Distributed chemical sensing is emphasized based on recent studies as a promising method to detect early corrosion onset and monitor corrosive environments for corrosion mitigation management. Additionally, challenges are discussed including durability and stability in extreme and harsh conditions such as high temperature high pressure in subsurface wellbores.

passive RFID sensors↗

DOE OSTI2024

Calcined Polyethyleneimine Coated Optical Fibers for Distributed pH Monitoring at High Pressures and Temperatures

In the oil and gas, CO2 sequestration, H2 subsurface storage, and geothermal energy sectors, subsurface pH measurements are critical for monitoring the geochemical conditions and estimating potential corrosion rates of wellbore systems. Real-time pH measurements in these conditions are vital for detecting and predicting corrosion deterioration of wellbore components that may jeopardize the safety and continued operation of wellbore systems. Building off of earlier TiO2 based pH sensors and the known pH sensitivity of amine-based polymers, a coating based on the secondary amine polymer polyethyleneimine (PEI) was developed. The sensor coating was treated with a high temperature (500 °C) calcination procedure in air to convert it into a more stable oxidized coating capable of withstanding hot aqueous solutions without dissolving while retaining linear pH sensitivity from pH values between 2 and 11. The sensor performance was measured using optical transmission measurements in solutions of various pHs and using optical backscatter reflectometry for distributed pH sensing demonstration in wellbore-relevant pressures (up to 1000 psi) and temperatures (80 °C). A calibration curve with strong differentiation between acidic and alkaline pH was developed for both transmission-based and distributed pH measurements, using fixed wavelength transmission and integrated linear amplitude of backscattered light for distributed measurements.

Shumski, Alexander↗

DOE OSTI2020

Integrating Radio-Over-Fiber Communication System and BOTDR Sensor System

In this paper, we propose and experimentally demonstrate for the first time, the integration of a radio-over-fiber (RoF) communication system and a Brillouin optical time-domain reflectometry (BOTDR) distributed sensor system using a single optical fiber link. In this proof-of-concept integrated system, the communication system is composed of three modulation formats of quadrature phase-shift keying (QPSK), 16-quadrature amplitude modulation (16-QAM) and 64-QAM, which are modulated onto an orthogonal frequency division multiplexing (OFDM) signal. Whereas, the BOTDR sensor system is used for strain and/or temperature monitoring over the fiber distance with a spatial resolution of 5 m using a 25 km single-mode silica fiber. The error vector magnitude (EVM) is analyzed in three modulation formats in the presence of various BOTDR input pump powers. Using QPSK modulation, optimized 18 dBm sensing and 10 dBm data power, the measured EVM values with and without bandpass filter are 3.5% and 14.5%, respectively. The proposed system demonstrates a low temperature measurement error (±0.49 °C at the end of 25 km) and acceptable EVM values, which were within the 3GPP requirements. The proposed integrated system can be effectively applied for practical applications, which significantly reduces the fiber infrastructure cost by effective usage of a single optical fiber link.

42 ENGINEERING↗

NASA NTRS1987

Fiber optic and laser sensors IV; Proceedings of the Meeting, Cambridge, MA, Sept. 22-24, 1986

The conference presents papers on industrial uses of fiber optic sensors, point and distributed polarimetric optical fiber sensors, fiber optic electric field sensor technology, micromachined resonant structures, single-mode fibers for sensing applications, and measurement techniques for magnetic field gradient detection. Consideration is also given to electric field meter and temperature measurement techniques for the power industry, the calibration of high-temperature fiber-optic microbend pressure transducers, and interferometric sensors for dc measurands. Other topics include the recognition of colors and collision avoidance in robotics using optical fiber sensors, the loss compensation of intensity-modulating fiber-optic sensors, and an embedded optical fiber strain tensor for composite structure applications.

De Paula, Ramon P.↗

NASA NTRS2003

Micro-optical Distributed Sensors for Aero Propulsion Applications

The objective of this research is to develop micro-opto-mechanical system (MOMS)-based sensors for time- and space-resolved measurements of flow properties in aerodynamics applications. The measurement technique we propose uses optical resonances in dielectric micro-spheres that can be excited by radiation tunneling from optical fibers. It exploits the tunneling-induced and morphology-dependent shifts in the resonant frequencies. The shift in the resonant frequency is dependent on the size, shape, and index of refraction of the micro-sphere. A physical change in the environment surrounding a micro-bead can change one or more of these properties of the sphere thereby causing a shift in frequency of resonance. The change of the resonance frequency can be detected with high resolution by scanning a frequency-tunable laser that is coupled into the fiber and observing the transmission spectrum at the output of the fiber. It is expected that, in the future, the measurement concept will lead to a system of distributed micro-sensors providing spatial data resolved in time and space. The present project focuses on the development and demonstration of temperature sensors using the morphology-dependent optical resonances although in the latter part of the work, we will also develop a pressure sensor. During the period covered in this report, the optical and electronic equipment necessary for the experimental work was assembled and the experimental setup was designed for the single sensor temperature measurements. Software was developed for real-time tracking of the optical resonance shifts. Some preliminary experiments were also carried out to detect temperature using a single bead in a water bath.

Arnold, S.↗