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This presentation covers development of single crystal fibers and distributed temperature sensing system given at the NRC workshop.
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In this project, we have developed and tested three kinds of fiber optic sensing systems for real time monitoring of temperature variations within an industrial scale boiler furnace. The fiber optic sensing systems target spatial and temporal distributions of high temperature profiles in a boiler furnace in fossil power plants. The reconstructed temperature profile will provide critical input for the control mechanisms to optimize the combustion process. This temperature profile will address the essential problem for fossil power plants in achieving higher efficiency and fewer pollutant emissions. Acoustic pyrometer systems have been used to reconstruct temperature field of power plant boilers based on measuring TOF (times-of-flight) of sound waves along some straight paths in a 2D cross-section of the boiler. In this project, optically generated acoustic signals from a fiber optic sensing system have replaced the acoustic signals generated from an electrical transducer. A 3D reconstruction algorithm replaced the previous 2D model. In this project, three kinds of fiber optic sensing systems have been developed and tested. They are fiber optic sensing system I, fiber optic sensing system II (Distributed Sensing System I) and fiber optic sensing system III (Distributed Sensing System II). For fiber optic sensing system I, the fiber optic ultrasound generator acts as a signal generator. A microphone, hydrophone or other electronic devices serve as a signal receiver. In this system, there are one generator and one receiver. Distance test, water temperature test, air temperature test, air temperature reconstruction, and GE ISBF pilot test were performed by Fiber optic sensing system I. The fiber optic sensing system I successfully detected temperature in all these tests. We got 2D temperature reconstruction results by using the fiber optic sensing system I and it matched the reference data. The fiber optic sensing system I successfully survived in GE ISBF boiler environment (480 °F). For fiber optic sensing system II (Distributed Sensing System I), it is an all optical ultrasound system. The fiber optic ultrasound generator acts as a signal generator. Fiber Bragg Grating (FBG) and Fabry-Perot (FP) sensor act as a signal receiver. In this system, there is one generator and one receiver. Aluminum plate temperature test, furnace high temperature test, and GE ISBF pilot test were performed by the fiber optic sensing system II. Fiber optic sensing system II successfully detected the temperature in all these tests. The fiber optic sensing system II successfully survived at up to 700 °C furnace environment and 320 °C GE ISBF boiler environment. For fiber optic sensing system III (Distributed Sensing System II), it is also an all optical ultrasound system. The fiber optic ultrasound generator acts as a signal generator. Multiple FP fiber sensors act as signal receivers. In this system, there is one generator and three receivers. Three GE ISBF pilot tests were performed by fiber optic sensing system III. The fiber optic sensing system III survived in the cold flow tests in GE’s ISBF pilot test facility. However, we didn’t get high temperature data by using this system since the nanosecond laser issues. During the period of the project, test trials, data simulation and algorithm optimization was performed successfully. For real time temperature field construction, the sampling rate must be fast enough to capture the field variations. The technology of Code-division multiple access (CDMA) is well studied which could allow parallel multiplexing, even if signals overlap in time or frequencies. Moreover, it has been known that extending the length of signal significantly improves SNR. For acoustic signals, these multiplexing techniques have also been widely used, mainly for sonar and acoustic communications. The CDMA modulation technique has been proposed and studied to guarantee high network throughput, low channel access delay and low energy consumption. We have studied the temperature field reconstruction using Gaussian Radial Basis Functions (GRBF)-based approximation approach. Reconstruction of 3D temperature field using Neural Networks with measured TOF and known propagation paths is feasible. 2D and 3D temperature field reconstruction simulation results are achieved. The milestone status is shown in Table 1. We finished milestone 1-8 and milestone 10. For milestone 9, we did three pilot tests by using the fiber optic sensing system III (Distributed Sensing System II) at GE Power. However, due to the failure of the ns laser, we did not get the temperature results. We conducted some additional tasks that were not originally proposed: 1) We fabricated a fiber optic sensing system I and did a pilot test based on this system. 2) In the proposal, we proposed two pilot tests at GE Power. In reality, we finished at least seven pilot tests at GE Power. GE Power has made a lot of efforts for supporting the pilot tests. 3) We got a simulation results based on CDMA. In summary, most of the tasks have been accomplished. The outcome of this project removed a few barriers that hinder the achievement of the final product of the distributed sensing systems. With the successful accomplishment of this project, a prototype of the fiber optic sensing system can be fabricated to attract more interests from companies and other funding agencies.
The National Energy Technology Laboratory (NETL) and Colonial Pipeline Company (Participant) will collaborate in the field demonstration of optical fiber sensor systems developed at NETL on Participant’s fuel pipeline. The optical fiber sensor technologies are capable of distributed temperature and strain sensing, distributed acoustic sensing, and ultrasensitive acoustic sensing. Real-time monitoring of these parameters enables pipeline integrity monitoring, security monitoring, flow rate monitoring, etc. Successful demonstration on a real fuel pipeline at Participant’s facilities will validate the sensor technologies and installation methods at a real scale. This effort aligns with NETL’s mission in reliable and sustainable energy and reducing environmental effects due to pipeline failures.
This research reports a distributed fiber optic high-temperature sensing system tailored for applications in the steel industry and various other sectors. Recent advancements in optical sensor technology have led to the exploration of sapphire crystal fibers as a solution for sensing in harsh environments. Utilizing a femtosecond (fs) laser, cascaded fiber Bragg gratings (FBGs) were meticulously fabricated within a multimode sapphire optical fiber. These FBGs endowed the system with distributed sensing capabilities and underwent rigorous testing under extreme temperatures, reaching up to 1800 °C. Here, the study delves into the investigation of the FBG reflection spectrum, facilitated by the development of a sophisticated multimode demodulation system, which contributed to the attainment of precise temperature measurements with a performance accuracy of 99.9%. Demonstrating exceptional thermal stability, the sapphire FBGs endured temperatures of 1600 °C for a sustained duration of 22 h. Furthermore, this article explores the application of distributed temperature sensing employing multiple sapphire FBGs, showcasing their utility in temperature measurements related to molten steel studies.
Distributed temperature-sensing data collected using a Silixa-XT DTS and 50/125 MM fiber. Data are calibrated using two water baths at the surface and an iMet aloft at the end of the fiber and tether. The data are then assigned an altitude for the TBS flight.
Fracture is an important component of nuclear fuel behavior, and significant efforts have been invested into developing fuel performance models that are capable of accurately representing fracture. Usable data on the process of fracture propagation in nuclear fuel under realistic service conditions are very limited. To address this need, a series of separate-effects experiments were developed and performed at Idaho National Laboratory's Transient Reactor Test (TREAT) facility. These experiments employ a heat sink to radially remove heat from the fuel in a manner that approximates the effect of coolant in an operating light-water reactor (LWR). The test holder for these experiments is known as the Dry In-pile Fracture Test (DRIFT). A series of experiments employing DRIFT and TREAT were performed to provide data on the extent and nature of fracture in fresh fuel at various points during a ramp to full power. Novel aspects of these experiments include the way they employ a heat sink to replicate steady-state LWR conditions, as well as the use of fiber optic sensors for in-reactor thermal instrumentation. Details on the development of this experiment, experimental conditions, and resulting data (including in situ thermal measurements and post-irradiation imaging of fracture) are provided in this work. LWR-equivalent powers ranging from 10 to 25 kW/m were tested using this apparatus. Cracking was visible at all power levels, with increasing cracking extent as the power level increased, although there was little difference in the cracking between the two highest-power tests, which had LWR-equivalent powers of 20 and 25 kW/m.
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Monitoring the injected CO 2 during geological CO 2 storage (GCS) is essential to assure containment and identify CO 2 leakage. Here in this work, a new approach is introduced to estimate the evolution of the downhole fluid velocity at a monitoring well and identify CO 2 arrival time using in-well heat pulse/tracer test. The proposed technique involves using a downhole heater to generate a series of heat pulses and measuring their corresponding temperature response. The surface temperature of the downhole heater is controlled by the supplied electrical power and the heat loss by convection to the surroundings. Convective heat transfer is well described using Newton's law of cooling in which the temperature difference between the heater and the surrounding fluids drives the heat transfer, for which the convection heat transfer coefficient (h) controls the magnitude of heat loss. Among various factors that control h, it depends on the type of the flowing fluid and its velocity. Through analyzing the measured temperature at different heat pulses, the changes in h - due to mobilization of the in-situ brine or CO 2 arrival - can be estimated. Consequently, the velocity of the flowing fluid across the heater can be obtained. Since heat transfer by convection is sensitive to the type of the surrounding fluid, intrusion of CO 2 can be detected from the relatively higher surface temperature obtained at CO 2 arrival. Churchill and Bernstein (1977)'s correlation is adopted to estimate the change of fluid velocity in terms of the change in h. To demonstrate the validity of the proposed technique, the results are applied and validated against those of COMSOL Multiphysics simulation tool for single-phase brine (before CO 2 arrival) and single-phase CO 2 (after CO 2 arrival). The observed temperature heating is sensitive to the flowing fluid velocity and fluid type. The temperature signal observed at CO 2 arrival is large and easily detectable using temperature monitoring tool which provides reliable indication for tracking CO 2 arrival at monitoring wells compared with passive temperature monitoring. The results obtained using the proposed technique agree very well with the numerical results obtained from the simulation tool with a maximum estimation error of 7 percent.
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Distributed temperature-sensing data collected using a Silixa-XT DTS and 50/125 MM fiber. Data are calibrated using two water baths at the surface and an iMet aloft at the end of the fiber and tether. The data are then assigned an altitude for the TBS flight. Data collected prior to Febuary 11, 2020 were collected at the SGP Central Facility (CF). Data from 2/11/20 were collected with a Sensornet Oryx DTS at the E9 site, not at the CF. Data from May 2021 were collected with a Sensornet Oryx at the CF, and with a Silixa XT at the CF. Data from July 2021 were collected at the SGP CF, EF9, and EF36 with a Silixa XT. Data from October 2021 were collected at the SGP EF36 with a Silixa XT. Data from February 2022 were collected at the CF with a Silixa XT.
It is crucial to monitor the CO2 plume effectively throughout the life cycle of a geologic CO2 sequestration project to ensure safety and storage efficiency. However, the computational cost of existing data assimilation methods can be prohibitively expensive due to the complex physics with multi-component non-isothermal simulation and high dimensionality of large-scale reservoir models. We address this challenge by proposing an accelerated deep learning-based workflow for model calibration and prediction of CO2 plume evolution in the reservoir.The power and efficacy of our workflow is demonstrated by application to the Illinois Basin-Decatur Project (IBDP), a large-scale CO2 storage test in saline aquifer. The data assimilation process is implemented rapidly by the proposed workflow with given field measurements including distributed pressure and temperature sensing (DTS) data at an injection and a monitoring well. CO2 plume evolution is predicted by running the simulations of the calibrated reservoir models.
Overview and brief project update on 3 tasks within the RIC Advanced Sensors & Controls FWP with direct applications to coal fired boiler temperature sensing. Task 32, Field demonstration of distributed temperature measurement with optical fiber for fossil energy power generation applications. Task 47, In-situ temperature measurements via reactive particles. Task 48, Ultrafast laser measurements for power generation environments.
Summary Low-frequency distributed acoustic sensing (LF-DAS) exploits the optical phase shift of Rayleigh backscatter in fiber-optic cables to obtain distributed measurements of changes in strain and temperature. Fiber-optic cables are often installed for multistage hydraulic fracture diagnostics in horizontal wells. LF-DAS in an untreated well provides far-field strain measurements, while offset wells are hydraulically fractured. Such a configuration is called crosswell LF-DAS sensing. Crosswell LF-DAS measurements have proved useful in diagnosing fracture hits, fracture azimuth, planarity, cluster efficiency, fracture propagation rates, and the dynamic distance to the fracture front. In contrast, in-well LF-DAS is conducted on the actively fractured well. Due to cool fracture fluid being injected at high injection rates, the strain component of the LF-DAS response is largely obscured by temperature changes. In permanent fiber-optic cable installations, distributed temperature sensing (DTS) is often conducted simultaneously with LF-DAS. An opportunity exists to decouple the temperature and strain components of LF-DAS sensors to observe strain changes on in-well LF-DAS. The LF-DAS response is modeled as linearly dependent on strain and temperature changes. Theoretical LF-DAS temperature and strain sensitivity coefficients are derived based on the changes to the index of refraction and length of the fiber. Using the DTS measurements, temperature changes are computed, smoothed, filtered, and compared to the LF-DAS response. Crossplots of the in-well LF-DAS measurements and temperature changes from DTS measurements far from the actively fractured region are used to validate the theoretical sensitivity coefficients. Uncertainty in the temperature component of the LF-DAS response is quantified. The difficulty in corresponding the different spatial and temporal resolutions of the DTS and LF-DAS measurements is overcome by comparing the responses over a moving temporal and spatial window. If the LF-DAS response at the center of the window agrees with the DTS response within uncertainty, the measurement is filtered out. After filtering, the remaining nonzero in-well LF-DAS measurements are due to changes in strain. The data are then visualized in waterfall plots. The results indicate that the theoretical and observed strain and temperature coefficients agree within 10%. After the temperature component of the in-well LF-DAS response is extracted, the remaining nonzero measurements are located primarily within the actively treated region. Locations with peaks in the strain response are interpreted to indicate fracture initiation points. These fracture initiation points are compared with in-well DTS and high-frequency DAS noise measurements across multiple stages to better understand fracture initiation along the horizontal well.
High-temperature superconductors, such as REBa2Cu3O7−x (REBCO, RE = rare earth), are becoming pivotal for high-field magnet technology for future circular colliders and compact fusion reactors. The U.S. Magnet Development Program, in collaboration with industry, is developing REBCO magnet technology using round conductors consisting of multiple REBCO tapes. For these multi-tape cables, traditional instrumentation, such as voltage taps and resistive strain gauges, become insufficient to help measure and understand the performance-limiting factors in these model magnets. Distributed fiber-optic sensing (DFOS) is a potential solution to address this challenge. Although DFOS is well established for various applications, measuring temperature and strain in high-temperature superconducting magnets is in its infancy. Here we report the detailed implementation and test results of DFOS based on Rayleigh scattering in a subscale canted cosθ (CCT) dipole magnet using high-temperature superconducting CORC® wires. We co-wound optical fibers in each layer of the CCT magnet and compared different types of commercial fibers and mold-release agents to reduce the power attenuation in the fibers. The DFOS allowed us to measure mechanical deformation and temperature along the conductor during tests at 77 and 4.2 K. The measured strain agreed quantitively with a finite-element mechanical model of the subscale magnet. Our results indicate that DFOS can effectively identify locations of strain and temperature changes, offering unique insight into magnet performance that can advance our understanding and development of the REBCO magnet technology for high-energy physics and fusion applications.
Distributed fiber optic sensing was an important part of the monitoring system for EGS Collab Experiment #2. A single loop of custom fiber package was grouted into the four monitoring boreholes that bracketed the experiment volume. This fiber package contained two multi-mode fibers and four single-mode fibers. These fibers were connected to an array of fiber optic interrogator units, each targeting a different measurement. The distributed temperature system (DTS) consisted of a Silixa XT-DTS unit, connected to both ends of one of the two multi-mode fibers. This system measured absolute temperature along the entire length of fiber for the duration of the experiment at a sampling rate of approximately 10 minutes. This dataset includes both raw data in XML format from the XT-DTS, as well as a processed dataset with the sections of data pertaining only to the boreholes are extracted. We have also included a report that provides all of the relevant details necessary for users to process and interpret the data for themselves. Please read this accompanying report. If, after reading it, there are still outstanding questions, please do not hesitate to contact us. Happy processing.