AI/ML-Enabled Advanced Distributed Optical Fiber Sensors
Distributed optical fiber sensors development integrated with AI/ML algorithms for energy infrastructure monitoring applications.
fiber optic sensors↗
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Glassy carbon formation from pyrolysis of polymeric coatings on fiber-optic sensors
Deploying fiber-optic sensors in nuclear reactors requires a detailed understanding of radiation effects on the fiber materials and the transmitted signals. Previous work has shown large wavelength shifts in the reflected spectra obtained from polymer-coated fiber-optic temperature sensors exposed to high neutron fluences. The sensor drift resulting from these wavelength shifts cannot be explained by radiation effects on fused silica glass. These shifts are hypothesized to be caused by the conversion of the polymeric fiber coating to a glassy carbon via radiolysis and/or pyrolysis and subsequent radiation-induced compaction. Here, thermal degradation of these polymeric coatings was studied to provide insight into the potential origins of the sensor drift phenomenon. Acrylate- and polyimide-coated fibers were heated under various temperatures (250–1300 °C) and environments (oxidative and inert), and the resulting coating products were characterized via mass-loss data, scanning electron microscope imaging, and Raman spectroscopy. Results suggest that the polymer decomposition product of both coating types, at least under inert conditions, is indeed a glassy carbon. Analytical models that account for radiation-induced glassy carbon coating compaction show significant compressive fiber strains and predicted wavelength shifts that agree well with experimental measurements, providing additional evidence that supports the hypothesized origins of the sensor drift.
36 MATERIALS SCIENCE↗
Advanced Distributed Optical Fiber Sensor Systems for Pipeline Integrity Monitoring
Distributed fiber optic sensors allow the measurement of structural parameters such as static/dynamic strain, temperature, pressure, and vibrations at thousands of locations along a single fiber cable. Deep neural network (DNN) algorithms were developed for rapid data processing speed and vibration event classification.
Lalam, Nageswara↗
Pilot-Scale Validation of Distributed Optical Fiber Sensors for Underground Pipeline Monitoring
Monitoring parameters such as hoop strain, pressure, and acoustic vibrations is key to detecting potential leaks, intrusions, or structural issues. Distributed optical fiber sensor (DOFS) systems provide a compelling solution for continuous, real-time monitoring over long distances. This paper details the development and pilot-scale implementation of DOFS systems for underground pipeline monitoring, evolving from a proof-of-concept stage. Multiple custom-designed DOFS interrogator units—such as optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain analysis (BOTDA), and multimodal interferometer-based fiber acoustic sensor systems were tested to measure the key parameters, such as hoop strain, pipe pressure, surrounding soil temperature, and acoustic vibrations. The underground product pipeline’s outer diameter is 30 inches, the wall thickness is 1.28 inches, and 3 feet deep from the surface. The fiber deployment strategies and sensing data acquisition methods for these systems are discussed. The results demonstrate the effectiveness of DOFS in detecting hoop strain, temperature changes, and acoustic vibrations, showcasing their potential for real-time monitoring and enhancing pipeline safety. These findings from pilot-scale testing offer valuable insights into advancing pipeline monitoring technologies and improving the reliability of underground pipeline systems.
fiber optic sensors↗
Testing and Characterization to Develop a Mechanistic Explanation for Unsaturated Drift of Fiber Optic Sensors during High-Dose Irradiation
The primary limitation for any optical fiber-based sensor for nuclear reactor applications is radiation-induced attenuation (RIA) of the transmitted and/or reflected signals. Based on several recent studies, RIA is tolerable for some fused silica optical fibers with the proper choice of sensing wavelength and fiber dopants. For extreme temperature applications (> 1000°C), sapphire optical fibers have been proposed; however, recent optical transmission measurements performed on bulk sapphire samples showed prohibitively large RIA. For some sensors, radiation-induced dimensional changes in the fiber materials can also cause significant drift. Moreover, the drift that was observed in numerous experiments performed in the High Flux Isotope Reactor (HFIR), the Advanced Test Reactor, the Massachusetts Institute of Technology Reactor, and other international facilities far exceeded what would be expected based on compaction of fused silica glass. Clearly, additional work is needed to better understand the origins of both RIA and radiation-induced drift in both silica and sapphire optical fiber-based sensors before these sensors can be reliably deployed for nuclear applications. This work evaluated the underlying mechanisms that may be responsible for RIA and drift in silica and sapphire materials. First, detailed characterization was performed on bulk fused silica glass samples that were previously irradiated to different neutron fluences at different temperatures to better understand the structural changes that drive radiation-induced drift in the absence of coating effects that are discussed later. Results show that the non-monotonic compaction that occurs with increasing neutron fluence continues up to fast neutron fluences approaching 10 22 n/cm 2 , which has important implications for physics-based models that may be used to compensate for the sensor drift. Initial Raman spectroscopy and synchrotron x-ray diffraction provide insights into the nature of the structural changes. Next, detailed characterizations were performed on silica fibers with various coatings that were subjected to several different thermal treatments. The hypothesis is that the coatings convert to carbon-rich materials that compact under irradiation, putting a large compressive strain on the fiber. Out-of-pile testing confirms that both polyimide and acrylate fiber coatings convert to glassy carbon (GC) materials when heated under inert conditions, and the degree of order (i.e., graphitization) increases with increasing temperature. The results provide increasingly strong evidence that the combination of polymeric coatings and inert (or vacuum) conditions render fiber optic sensors susceptible to significant radiation-induced drift that would not otherwise exist in uncoated fibers. Finally, transmission electron microscopy was performed on bulk sapphire samples that were irradiated to two neutron fluences at different temperatures to gain insights into the potential mechanisms driving the prohibitive RIA at higher neutron fluences and temperatures. Contrary to previous hypotheses, results show that scattering from radiation-induced voids cannot explain the observed RIA. Similarly, models for scattering losses from dislocation loops also do not agree with the experimental results. Instead, fitting to the experimental data shows that increased absorption from aluminum vacancy centers is the most likely explanation for the the prohibitively large RIA that was observed at high irradiation temperature and dose. In addition, the voids that formed in these single-crystal samples were found to align along the basal plane (a-axis) as opposed to that seen in previous observations of c-axis alignment in polycrystalline samples, which could have important implications for anisotropic swelling and other phenomena that could affect sensor performance at high neutron fluence.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Testing and Characterization to Develop a Mechanistic Explanation for Unsaturated Drift of Fiber Optic Sensors during High-Dose Irradiation
The primary limitation for any optical fiber-based sensor for nuclear reactor applications is radiation-induced attenuation (RIA) of the transmitted and/or reflected signals. Based on several recent studies, RIA is tolerable for some fused silica optical fibers with the proper choice of sensing wavelength and fiber dopants. For extreme temperature applications (> 1000°C), sapphire optical fibers have been proposed; however, recent optical transmission measurements performed on bulk sapphire samples showed prohibitively large RIA. For some sensors, radiation-induced dimensional changes in the fiber materials can also cause significant drift. Moreover, the drift that was observed in numerous experiments performed in the High Flux Isotope Reactor (HFIR), the Advanced Test Reactor, the Massachusetts Institute of Technology Reactor, and other international facilities far exceeded what would be expected based on compaction of fused silica glass. Clearly, additional work is needed to better understand the origins of both RIA and radiation-induced drift in both silica and sapphire optical fiber-based sensors before these sensors can be reliably deployed for nuclear applications. This work evaluated the underlying mechanisms that may be responsible for RIA and drift in silica and sapphire materials. First, detailed characterization was performed on bulk fused silica glass samples that were previously irradiated to different neutron fluences at different temperatures to better understand the structural changes that drive radiation-induced drift in the absence of coating effects that are discussed later. Results show that the non-monotonic compaction that occurs with increasing neutron fluence continues up to fast neutron fluences approaching 10 22 n/cm 2 , which has important implications for physics-based models that may be used to compensate for the sensor drift. Initial Raman spectroscopy and synchrotron x-ray diffraction provide insights into the nature of the structural changes. Next, detailed characterizations were performed on silica fibers with various coatings that were subjected to several different thermal treatments. The hypothesis is that the coatings convert to carbon-rich materials that compact under irradiation, putting a large compressive strain on the fiber. Out-of-pile testing confirms that both polyimide and acrylate fiber coatings convert to glassy carbon (GC) materials when heated under inert conditions, and the degree of order (i.e., graphitization) increases with increasing temperature. The results provide increasingly strong evidence that the combination of polymeric coatings and inert (or vacuum) conditions render fiber optic sensors susceptible to significant radiation-induced drift that would not otherwise exist in uncoated fibers. Finally, transmission electron microscopy was performed on bulk sapphire samples that were irradiated to two neutron fluences at different temperatures to gain insights into the potential mechanisms driving the prohibitive RIA at higher neutron fluences and temperatures. Contrary to previous hypotheses, results show that scattering from radiation-induced voids cannot explain the observed RIA. Similarly, models for scattering losses from dislocation loops also do not agree with the experimental results. Instead, fitting to the experimental data shows that increased absorption from aluminum vacancy centers is the most likely explanation for the the prohibitively large RIA that was observed at high irradiation temperature and dose. In addition, the voids that formed in these single-crystal samples were found to align along the basal plane (a-axis) as opposed to that seen in previous observations of c-axis alignment in polycrystalline samples, which could have important implications for anisotropic swelling and other phenomena that could affect sensor performance at high neutron fluence.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Distributed strain sensing using Bi-metallic coated fiber optic sensors embedded in stainless steel
Silica fiber optic sensors are resistant to corrosive environments and high temperatures, making them attractive candidates for harsh conditions found in nuclear and aerospace industries. Moreover, fibers can be deployed remotely for continuous measuring of spatially distributed temperatures and strains. Here, this study investigated embedding a Ni/Cu bi-metallic coated fiber in a stainless-steel 316 (SS316) matrix using laser powder bed fusion towards functionalizing metal components for site-specific health monitoring. The embedded fiber was continuously interrogated during controlled heating to 1000°C. The measured fiber strains were similar to the expected differential thermal strains between the fiber and the SS316 matrix, until divergent behavior was observed at temperatures >500°C. No debonding at the matrix–coating–fiber interfaces was observed during microscopy, but significant interactions between the coatings and matrix resulted in diffusion-driven chemistry variations and Kirkendall void formation. Applying the strain-lag theory revealed plastic behavior in the Ni coating at temperatures >500°C, limiting the strain transfer to the fiber at higher temperatures. It was estimated that the elastic modulus in the Ni coating had decreased from ~200 GPa at room temperature to below 40 GPa, starting at 600°C. The low elastic modulus above 600°C is within the margin of what the tangent modulus would be in the case of bilinear isotropic hardening. Regardless of the divergent strain transfer at higher temperatures, the fiber was exposed to the equivalent of 1.9 % engineering strain at 1000°C, but measured only a 0.7 % engineering strain due to the poor strain transfer. Although compensating for the plastic behavior of Ni proved challenging, the bonding of a brittle silica fiber to a metal matrix surviving to 1000°C invites potential iterations on coating material for future application. For example, the embedded fiber is sufficient for acoustic energy transfer, realizing high temperature distributed acoustic sensing.
36 MATERIALS SCIENCE↗
Embedded Fiber Optic Sensors in Structural Materials for Sensing in Extreme Environments
This slide deck presents the research results in embedding fiber optic sensors in structural materials. Fiber optic sensors were embedded in stainless steel and nickel via electric field assisted sintering. The embedded sensors were evaluated in terms of fiber integrity, fiber-matrix bonding, fiber functionality, mechanical properties, and machinability.
36 - MATERIALS SCIENCE↗
Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring
Not Available
36 MATERIALS SCIENCE↗
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↗
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↗
Pilot-Scale Validation of Distributed Optical Fiber Sensors for Underground Pipeline Monitoring
Distributed fiber optic sensing is a cutting-edge technology that has found extensive applications in the monitoring of Ensuring the safety, integrity, and operational efficiency of underground product pipelines is vital for maintaining the nation’s critical infrastructure. Monitoring parameters such as hoop strain, pressure, and acoustic vibrations is key to detecting potential leaks, intrusions, or structural issues. Distributed optical fiber sensor (DOFS) systems provide a compelling solution for continuous, real-time monitoring over long distances. This paper details the development and pilot-scale implementation of DOFS systems for underground pipeline monitoring, evolving from a proof-of-concept stage. Multiple custom-designed DOFS interrogator units—such as optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain analysis (BOTDA), and multimodal interferometer-based fiber acoustic sensors—were employed to measure key parameters like hoop strain, pressure, and acoustic vibrations. The underground product pipeline's outer diameter is 30 inches, the wall thickness is 1.28 inches, and the 3-foot depth. The fiber deployment strategies, and sensing data acquisition methods for these systems are discussed. The results demonstrate the effectiveness of DOFS in detecting hoop strain, temperature changes, and acoustic vibrations, showcasing their potential for real-time monitoring and enhancing pipeline safety.
distributed fiber sensing↗
AC Magnetometry Using Nano-ferrofluid Cladded Multimode Interferometric Fiber Optic Sensors for Power Grid Monitoring Applications
The AC magnetic field response of the superparamagnetic nano-ferrofluid is an interplay between the Neel and Brownian relaxation processes and is generally quantified via the susceptibility measurements at high frequencies. The high frequency limit is dictated by these relaxation times which need to be shorter than the time scale of the time varying magnetic field for the nano-ferrofluid to be considered in an equilibrium state at each time instant. Even though the high frequency response of ferrofluid has been extensively investigated for frequencies up to GHz range by non-optical methods, harnessing dynamic response by optical means for AC magnetic field sensing in fiber-optic-based sensors-field remains unexplored. Instead, the incorporation of nano-ferrofluid as sensing materials has been only limited to DC magnetic field sensing, often citing their long response time as a limiting factor to AC field sensing. This work reports the finding of high frequency (up to 15 kHz) AC magnetic field sensing capability of nanomagnetic fluid as the cladding material of a fiber-optic multimode interferometry (MMI) structure optimized for the fourth self-imaging spectral response. The key parameter enabling high frequency response is the short response time (<1 ms) achieved by optimizing both the sensing structure and nano-ferrofluid solution. Focus has been imparted on 60 Hz line-frequency profiles of various current/magnetic fields to test the efficacy of these sensors in metering and monitoring current and current-induced magnetic fields in the electrical power grid systems. The magnetic field sensitivity of 240 mV/Gauss per dBm of transmitted power was achieved for 60 Hz field applied via Helmholtz coil, whereas the 60 Hz AC current sensitivity of 2.83 mV/A was measured due to magnetic field induced by current in a straight conducting wire.
42 ENGINEERING↗
Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors
A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.
Bottom Anode↗
Optical Fiber Sensor with a Hydrophobic Filter Layer for Monitoring Hydrogen under Humid Conditions
Real-time and remote monitoring of hydrogen concentration in underground hydrogen storage reservoirs is crucial to maintaining the integrity and safety of the storage facilities. High humidity in the underground deposits interferes with hydrogen sensors, introducing inaccuracy into the hydrogen sensing measurements. A hydrophobic filter layer over a hydrogen sensing layer on an optical fiber hydrogen sensor was devised to minimize the impact of the humidity on the sensor. The hydrogen sensor coated with a hydrophobic filter layer demonstrated a significant improvement in reliable hydrogen sensing under high humidity conditions (99% RH) without severe baseline drift and reduction of transmission intensity. Finally, the optical fiber hydrogen sensor revamped with the filter layer would enable the reliable measurement of hydrogen concentration under the humid conditions expected in subsurface hydrogen storage facilities.
08 HYDROGEN↗
Fiber-Optic Sensor System for Multipoint Pressure and Temperature Measurement
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46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
H2 Sensing with an Optical Fiber Sensor in the Subsurface H2 Storage Conditions
The concentration of hydrogen is subject to change due to biological reactions in the underground hydrogen storage reservoirs. Thus, monitoring hydrogen concentration in the subsurface gas deposits is vital to ensure the integrity and safety of the storage facilities. In this study, the optical fiber hydrogen sensor was developed and validated in relevant subsurface storage environments. Specifically, the sensor has demonstrated successful sensing performance at high temperatures (~80 °C) and high pressures (~1,000 psi) under very humid conditions (~100% RH). In addition, the sensor was exposed to real subsurface microbial samples to monitor microbially induced changes in hydrogen concentration. The sensor has shown stable H2 sensing responses in the replicated underground hydrogen storage conditions without deterioration or loss of H2 sensitivity. The biotic subsurface sample with hydrogen gas resulted in higher transmission intensity change than the abiotic sample due to the possible hydrogen consumption with microbes.
Kim, Daejin↗
Advancing Temperature Monitoring of the Bottom Anode in a Direct Current Electric Arc Furnace Operations with Distributed Optical Fiber Sensors.
The bottom anode in the Direct Current Electric Arc Furnace (DC EAF) is critical for completing the electrical circuit necessary for sustaining the arc within the furnace. For pin-type bottom anodes, monitoring of the temperature of select pins instrumented with thermocouples is performed to track bottom wear in the EAF and inform the operator when the furnace should be removed from service. Furthermore, this work presents the results from a plant trial using distributed temperature monitoring of bottom anode pins in a 165-ton DC EAF over a two-month service period utilizing two optical fiber sensing techniques: fiber Bragg grating (FBG) and Rayleigh backscattering (RBS). The early detection of temperature anomalies along the length of the anode pin through distributed sensing enhances operational safety, providing a robust alternative to traditional thermocouples.
42 ENGINEERING↗