Distributed Fiber-Optic Sensors for Pipeline Inspection and Monitoring


26
Distributed Fiber-Optic Sensors for Pipeline Inspection and Monitoring


Nageswara Lalam1,2 and Ruishu Wright1


1National Energy Technology Laboratory, Pittsburgh, PA, USA


2NETL Research Support Contractor, Pittsburgh, PA, USA


26.1 Introduction


The field of fiber-optic sensors (FOS) for pipeline inspection and monitoring has witnessed significant advancements, positioning it at the forefront of pipeline infrastructure management. For point, quasi-distributed, and distributed sensing applications, a wide range of FOS technologies have been developed to monitor different physical (strain, temperature, and vibration) and chemical (corrosion, pH, gas species, etc.) parameters. Fiber Bragg grating (FBG), long-period grating (LPG), microstructured fibers, fiber ring lasers, multimode interference, Mach-Zehnder interferometer (MZI), Fabry–Perot interferometer, Michelson, and Sagnac interferometer are the examples of discrete fiber sensor architectures [14]. The use of distributed fiber-optic sensors (DFOS) has grown significantly and attracted much attention throughout the past decades. Based on Rayleigh, Brillouin, and Raman scatterings, DFOS provides a cutting-edge technique for spatially resolved distributed measurements [5, 6]. A compound annual growth rate (CAGR) of 6.4% is predicted for the DFOS market, which was valued at USD 1.35 billion in 2021 and will rise to USD 2.5 billion by 2030. Among various application industries, the oil and gas segment dominated the industry with a revenue share of more than 35.40% in 2022 [7].


The adoption of DFOS has become widespread for continuous monitoring along the entire length of pipelines [8]. This technology enables the detection of temperature, strain, acoustic signals, and chemical composition (e.g., corrosion) at every point along the fiber-optic cable, providing a real time and spatially resolved profile of the pipeline’s condition. Applications range from leak detection to the identification of structural deformations. By enabling predictive maintenance and reducing the need for manual inspections, these sensors help operators optimize resources, minimize downtime, and extend the lifespan of pipeline assets. The schematic representation of pipeline integrity measurement capabilities using the DFOS system is illustrated in Figure 26.1. The fiber installation of distributed sensors for the pipeline acts as a major difficulty to the growth of the DFOS, especially for retrofitting DFOS to existing pipelines. For pipeline integrity monitoring, the installation and protection of fiber-optic cables need proper protocols to ensure high-quality sensor data collection. The fiber-optic cable is typically installed alongside the pipeline, and it can be challenging to install the fiber-optic cable inside the pipeline, especially for existing buried pipes. In 2022, N. Lalam et al. [9] demonstrated a robotic fiber-optic deployment tool (FODT) for internal deployment to pipelines. This FODT internal deployment tool demonstration with distributed sensing offers a substantial retrofitting option for existing pipelines.


Compared to point sensors, DOFS enables continuous real-time monitoring over the entire pipeline length with reduced cost per unit of length. DOFS systems are based on the light backscattering along the optical fiber length. The interrogator acts as the source of light and the detector of the reflected signal, and the fiber-optic cable serves as both the sensor and the data transmission medium simultaneously. By examining the modulated backscattered signal, a distributed measurement throughout the entire fiber length can be constructed: a one-dimensional array of measurements along a single optical fiber. There are three kinds of backscattering signals originating from the fiber optic cable: Rayleigh, Brillouin, and Raman scattering. By interrogating different backscattered signals, different interrogators can be developed such as phase-sensitive optical time-domain reflectometry (Φ-OTDR), optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain reflectometry (BOTDR), Brillouin optical time-domain analysis (BOTDA), and Raman-based distributed temperature sensor (Raman-DTS) with various ranges of interrogation lengths and spatial resolutions. For the long-distance (tens of kilometers) strain and/or temperature measurements, BOTDR based on spontaneous Brillouin scattering and BOTDA based on stimulated Brillouin scattering are widely recognized techniques. Whereas, for a shorter range (100s of meters) and high spatial resolution, Brillouin optical correlation-domain reflectometry (BOCDR) based on laser external modulation and OFDR based on laser wavelength sweeping are the most recognized technologies [10, 11]. Rayleigh-based Φ-OTDR [also called distributed acoustic sensing (DAS)] is a widely adopted technique, particularly for pipeline monitoring applications. Table 26.1 illustrates the main DFOS sensing systems with their distinct sensing performances that are utilized to monitor various parameters.

A distributed fibre-optic sensing system is represented alongside a fibre-optic cable inserted within a pipeline. Backscattered light is used to collect spatially resolved sensing information, including leak detection, developing cracks or deformation, temperature distribution, and seismic events or intrusion detection. The monitoring system operates in real-time, 24 bar 7, and facilitates corrosion and humidity monitoring, as well as ground movement monitoring. Accompanying icons illustrate strain, temperature, and vibrations related to various activities around the pipeline.

Figure 26.1 Schematic of distributed fiber-optic sensor system for pipeline integrity monitoring.


(Reference [9].)


26.2 Distributed Strain and Temperature Sensing


In this section, we discuss the operating principles, and pilot-scale demonstrations of DFOS sensors, and their crucial role in ensuring pipeline infrastructure safety and reliability. In the field of pipeline monitoring and inspection, distributed strain and temperature measurements are essential for safeguarding the integrity and resilience of critical pipeline infrastructure.


By utilizing the inherent characteristics of optical fibers, such as Rayleigh, Brillouin, and Raman scattering, these sensors can provide physical perturbations, such as strain, temperature, acoustic vibration, pressure, etc., along the entire length of the fiber. The combination of strain and temperature sensors enhances the precision of leak detection, enabling rapid response to minimize environmental impact. Distributed strain sensing (DSS) enables the early detection of deformations, stress concentrations, and potential integrity threats. Distributed temperature sensing (DTS) provides insights into temperature variations, helping in the identification of hotspots, ensuring material integrity, and optimizing thermal performance [12]. As shown in Table 26.1, there are a few DFOS interrogators that can measure distributed strain or temperature, including BOTDR, BOTDA, OFDR, etc. Conventional single-mode FOS are widely adopted as a fiber under test for strain or temperature monitoring, and strain and temperature cannot be differentiated for single-mode FOS. In the literature, numerous methods have been demonstrated to show discriminative measurement of strain and temperature using specialty fibers. For instance, the use of multi-Brillouin peak fibers, few-mode fibers, double-core fibers, and photonic crystal fibers interrogated by BOTDR or BOTDA systems has been demonstrated for discriminative strain and temperature monitoring.


Table 26.1 Sensing Performance Comparison of Different Distributed Fiber-Optic Sensor (DFOS) Systems




















































Technology Sensing Range Spatial Resolution Measurement Time Measured Parameters
Brillouin-OTDR (BOTDR) Hundreds of kilometers Meter Minutes Strain, temperature
Brillouin-OTDA (BOTDA) Hundreds of kilometers Centimeter to meter Minutes Strain, temperature
Brillouin-OCDR (BOCDR) Hundreds of meters Centimeter Minutes Strain, temperature
Rayleigh-OFDR Meter to kilometer Micrometer to centimeter Seconds Strain, temperature, corrosion, gas composition
Rayleigh-OLCR Meter Millimeter Minutes Strain, temperature
Rayleigh Φ-OTDR or DAS Tens of kilometers Meter Seconds Vibration/dynamic strain
Raman-OTDR or DTS Tens of kilometers Meter Minutes Temperature only

The schematics of BOTDR and BOTDA sensing systems are depicted in Figure 26.2. The BOTDR system needs access to the single end of the sensing fiber and has straightforward implementation approaches. In contrast, the BOTDA system has complex system implementation and requires access to both ends of the sensing fiber. Based on stimulated Brillouin scattering, the BOTDA system makes use of a counter-propagating continuous wave coupled in the opposite directions of the same fiber. With coefficients of 1.18 MHz/°C for temperature and 0.05 MHz/με for strain of the silica fiber, respectively, the Brillouin frequency varies linearly with these changes [1315]. Therefore, the Brillouin frequency shift (BFS) can be used to calculate the strain or temperature changes around the sensing fiber [16].


DSS is critical for monitoring pipelines to detect and locate changes in strain or deformation along their length and is crucial for ensuring the structural integrity of the pipeline and for identifying potential issues before they become critical. DSS can be installed helically or longitudinally along the pipe and measure hoop strain or pipeline deformation caused by geohazards. The hoop strain (circumferential strain) of pipelines can serve as an indicator of inner pressure fluctuation and the wall thickness reduction of pipelines. One example is depicted in Figure 26.3. A fiber-optic cable (around 10 m in length) is wrapped around the pipeline and spliced to a 25 km long lead-in fiber and then connected to the BOTDA sensor system, where short pulses of light launch into the sensing fiber and backscattered signals are collected for analysis of physical quantities, such as hoop strain. The baseline measurement was first made at zero pressure before the pipeline was pressurized. To determine the distributed strain, a series of measurements were taken at various pressures up to 1000 psi. The relative backscattered BFS variation for different pipeline pressures is visible, as shown in Figure 26.4a. After calibration, the calculated change in pipeline hoop strain at various pipe pressures is illustrated in Figure 26.4b. Hoop strain changes at a specific location can be identified early, enabling proactive maintenance, and preventing potential failures, contributing to the overall integrity and safety of the pipeline infrastructure.

Diagrams a and b present setups for fibre-optic sensing using lasers and microwave generators. In a, the configuration includes a laser, coupler, and a depolarizer, interconnected with various components such as a microwave generator, a dual-drive Mach-Zehnder modulator, an erbium-doped fibre amplifier, and an amplified spontaneous emission filter. The signal travels through a sensing fibre before reaching a spectrum analyser. Diagram b integrates additional elements like a Mach-Zehnder modulator, pulse generator, isolator, and an oscilloscope, enhancing the sensing capabilities.

Figure 26.2 Schematics of DFOS. (a) BOTDR, (b) BOTDA for ultralong-distance interrogation for >100 km range.

A left section features a schematic diagram of a B O T D A sensor system connected to a laptop. A fibre cable runs through a steel pipe where gas flows, with a specification of 25 kilometres of single-mode fibre. The right section displays a close-up view of the steel pipe, where multiple installed fibres are highlighted. Horizontal and vertical markings on the pipe indicate areas of interest related to the fibre installation. Arrows point toward the installed fibres, emphasizing their arrangement along the pipe’s surface.

Figure 26.3 Pipeline hoop strain measurements. (a) Schematic illustration of a high-pressure natural gas pipeline with installed fiber-optic cable, and (b) Photograph of the pipeline with installed fibers.

A figure comprises two panels, a and b. Panel a features relative B F S change in megahertz plotted against fibre distance in kilometres for varying pipe pressures, baseline at 0 p s i, and pressures at one hundred, two hundred, four hundred, eight hundred, and one thousand p s i, represented by different line styles. Panel b presents a scatter plot of strain change in micro strain against pipe pressure in p s i. A linear fit line indicates a strong correlation, with a slope of zero point twenty-eight micro strain per psi, and an R-squared value of zero point ninety-eight.

Figure 26.4 Measured pipeline hoop strain at different pressures, (a) Brillouin frequency shift and corresponding hoop strain change over the installed fiber distance, and (b) average hoop strain change at various pipe pressures.


DTS can be used to detect and locate gas or liquid leaks from the pipelines. Using temperature changes for gas/liquid leak detection in pipelines offers a reliable and effective method for minimizing the risk of catastrophic failures, and ensuring pipeline safety. The DTS system provides continuous, real-time monitoring capabilities that are highly sensitive to temperature anomalies caused by the leaks. For example, because of the Joule-Thomson effect, leaks of pressurized natural gas would result in a cold spot, leading to a detectable temperature drop around the leak location. [17]. On the other hand, leaks of liquid natural gas (LNG) or other liquefied gases cause a phase change from liquid to gas. This phase transition absorbs heat from the surrounding environment, resulting in a significant local temperature drop [18]. Heating transportation is one way to reduce the viscosity to efficiently flow highly viscous crude oil in the pipes, and the leak of heated oil results in a temperature change outside the pipelines, which can be detected through DTS [19, 20]. It has been demonstrated in [21] that a DTS system provides an efficient way to detect and locate leakages along pipelines.


The BOTDA system was also used in an experimental field test for pipeline leakage detection through temperature monitoring conducted by OZ Optics Ltd. [22] in 2014. In their experiment, a 10.3 km long sensing fiber was loosely placed inside a metallic cable along with several buffer layers. To measure the temperature change before and after a leakage event, the sensing fiber was positioned 2.5 and 10 cm below the pipeline. A 15 ns pulsed source was used to achieve a 1.5 m spatial resolution. The Brillouin data was acquired every 4 min at a sampling rate of 250 MS/s. A baseline measurement was performed before the occurrence of any leaks. This baseline serves as a reference to which all subsequent measurements will be compared. Figure 26.5 shows the temperature changes induced when a large leak occurred at an injection pressure of 400 psi. Two peaks corresponding to two separate leaks occurred around 10.117 and 10.167 km. This demonstrated that DTS is an effective tool for locating leaks in pipeline applications. Furthermore, the system could find the leak within 2 min, which represents a vast improvement over manual inspection.


26.3 Distributed Acoustic Sensing


Pipeline monitoring is one of the many applications where DAS technology has grown in popularity. Along the pipeline’s length, acoustic waves are detected and analyzed using fiber-optic cables acting as sensors. A fiber-optic cable is installed along the pipeline route. This cable can be buried alongside the pipeline or attached to its surface. The fiber-optic cable serves as a continuous sensor, with the ability to detect acoustic signals, such as gas leaks, and third-party intrusion events. These can provide insights into the condition of the pipeline, helping operators schedule maintenance activities proactively. DAS relies on the principle of interferometry. When light pulses are sent through the fiber-optic cable, they interact with the acoustic signals along the cable. Changes in the backscattered light caused by the acoustic signals are analyzed to determine the location and characteristics of the disturbances.

An image consists of two sections labelled a and b. Section a features diagrams related to a pipeline system, highlighting sensing cable locations around a circular pipe. Measurements include a radius of two point five centimetres and a distance of ten centimetres. A standard telecom fibre is positioned along the pipeline, identifying simulated leak points. Section b presents a graph illustrating temperature change along a distance axis. Sharp peaks in temperature correspond to detected leaks, indicated by labelled arrows in the graph.

Figure 26.5 (a) Configuration of pipeline leakage monitoring using BOTDA system, (b) leakage detection snapshot with 400 psi injection pressure, soil temperature before test: 85 °F, line temperature: 115 °F.


(Reference [22]/with permission of OZ Optics Ltd.)


The experimental construction of the conventional Φ-OTDR system is illustrated in Figure 26.6a. A highly coherent narrow linewidth laser (NLL) operating at a wavelength of 1550 nm is used as a laser source. An external arbitrary waveform generator drives an acoustic-optic modulator (AOM) with a 200-MHz frequency shift to produce pump pulses after the light polarization is controlled by a polarization controller (PC). With an 80-kHz repetition frequency, the pulse width is set at 20 ns, giving 2 m of spatial resolution. Next, the output power is tuned for the sensing fiber’s input power level using an erbium-doped fiber amplifier (EDFA-1). To remove the amplified spontaneous emission (ASE) noise originating from the EDFA, a narrow band-pass filter with a bandwidth of 0.8 nm is employed. The pump pulses are then introduced into the sensor fiber via a circulator. After that, the Rayleigh backscattered signal is amplified by a second EDFA-2, while ASE noise and undesired sideband components are removed with a narrow band-pass filter. Thereafter, the signal is received by the 250-MHz bandwidth photodetector and digitized at 250 MS/s. The laboratory test pipe configuration is schematically illustrated in Figure 26.6b. At one end of the pipe section, a 2-in. outer diameter (OD), 10-foot-long steel pipe was wrapped circumferentially with a 3 m of standard single-mode fiber (SMF) and a 3 m of Rayleigh-enhanced fiber cable using a strong epoxy adhesive. In between, 15 m of delay fiber was employed, as shown in Figure 26.6b. The Rayleigh-enhanced fiber has improved the signal-to-noise ratio by 13 dB compared to SMF. To create well-controlled acoustic disturbances that travel the length of the pipe, a PZT (Lead Zirconate Titanate) transducer cylinder was fastened to one end of the pipe. The PZT was first powered by a low-frequency RF amplifier and a function generator. The PZT cylinder was excited sinusoidally at 20 kHz with an amplitude of 5 Vpp. Figure 26.7a depicts the reconstructed time-domain signals, where the axes display the fiber distance, time, and amplitude. By computing the fast Fourier transform (FFT) of the reconstructed time-domain signals at each position over the sensing fiber, the spatial-frequency 3D spectra were produced. Figure 26.7b displays the resulting frequency domain spectra. The Rayleigh-enhanced fiber cable and SMF were installed on the steel pipe at two different locations and are shown by the two peaks in Figure 26.7, which have respective locations of 1049 and 1064 m. Due to the installation of a 15-m delay fiber in the test pipe arrangement, there was a gap between these two fiber segments. Two peaks in the frequency and time-domain 3D spectra are depicted in the zoomed plot displayed in Figure 26.7 insets, which also accurately indicate the vibrations given to these two fiber segments (where PZT is driven by a 20-kHz frequency and 5 Vpp amplitude) [10].

A diagram illustrates a phase-Optical Time Domain Reflectometry experimental setup. Components include a narrow linewidth laser, an acousto-optic modulator, erbium-doped fibre amplifiers, and a photodetector. A function generator activates a R F amplifier linked to a P Z T transducer. The system includes a steel pipe connected to a Rayleigh-enhanced fibre cable, with S M F connections for signal propagation. Index-matching gel is used for effective signal transfer within the setup.

Figure 26.6 (a) Experimental setup of phase-OTDR (DAS) system, (b) schematic illustration of lab-scale pipe setup installed with SMF, Rayleigh-enhanced cable, and PZT excitation source, and (c) Picture of a laboratory pipeline test setup.


(Reference [10]/Springer Nature/CC BY 4.0.)

An image consists of two main panels labelled a and b, each presenting three-dimensional plots. Panel a features graphs with fibre length on one axis, amplitude in millivolts on another, and time in milliseconds on the third. An inset highlights a specific region of interest. Panel b illustrates a similar structure, displaying fibre length against frequency in kilohertz, also accompanied by an inset focused on a particular area. Both panels contain labelled axes with numerical coordinates, emphasizing their data points and relationships.

Figure 26.7 3D spectra at 20 kHz sinusoidal vibration on pipeline in (a) time-domain and (b) corresponding frequency domain. Insets: zoomed-in view of corresponding time/frequency domain plots of SMF and Rayleigh-enhanced fiber cable.


(Reference [10]/Springer Nature/CC BY 4.0.)


A field demonstration at a high-pressure loop natural gas pipeline under typical operating conditions was conducted after verifying the vibration sensing performance in the laboratory. Figure 26.8a shows the schematic diagram of the entire closed flow loop, natural gas flow test section with recirculating flow direction, installed fiber sensors, and simulated leak location. The test section pipe has an inner diameter (ID) of 4.5 in. and a length of 245 in. It was tested at 1000 psi and had set gas flow rates of 5, 10, 15, and 20 ft/s. Figure 26.8c provides an overall high-pressure loop natural gas test facility at Southwest Research Institute (SwRI), San Antonio, Texas. Using a strong adhesive glue, the sensing fibers were wrapped around the pipe at a specific pipe section. A 15-m delay fiber was placed between a 6-m SMF and Rayleigh-enhanced fiber cable. Figure 26.8b shows the installed fiber sections on the pipe, delay fiber, and lead-in SMF fiber spool. In addition, a commercial piezoelectric vibration sensor was installed on the pipe to compare its results with the Φ-OTDR system. The number of circumferential wraps on the pipe is higher than normal considering the length of the test pipe section. This boosted the fiber-to-pipe bonding coverage and, consequently, the measurement sensitivity for weak gas flow rates. Fiber installation along the pipe axis can be taken into consideration for longer-distance monitoring purposes.


At a fixed pipe pressure of 1000 psi and a flow rate of 5 ft/s, the vibrations caused by the varying gas flow are recorded. Figure 26.9 shows the reconstructed power spectral density plot. Figure 26.10 illustrates measured time-domain traces in the presence of gas flow of 5 ft/s and 1000 psi. The amplitude level of measured time trace using Rayleigh-enhanced fiber cable exhibits a wider range compared to the SMF and piezoelectric vibration sensor, which shows higher vibration sensitivity. The flow rate was increased to 10, 15, and 20 ft/s at a constant pressure of 1000 psi. The vibration traces that resulted from these changes were recorded using Rayleigh-enhanced cable, as shown in Figure 26.11.

A diagram consists of three sections labelled a, b, and c. Section a features a gas flow system with labelled components including a fibre sensors test section and a 4-inch schedule 160 carbon steel pipe, indicating dimensions. A note highlights a slow leak bleed location. In section b, a gas flow pipe with a phase-O T D R interrogator and lead-in fibre spool is present, along with a delay fibre. Section c displays various sensors, including a vibration sensor and an S M F, alongside Rayleigh-enhanced cable and flow and pressure meters, with identification of a leak location.

Figure 26.8 (a) Schematic diagram of the high-pressure loop natural gas pipeline system, (b) pipeline test section mounted with standard SMF, electrical vibration sensor, and Rayleigh-enhanced fiber cable, (c) overall high-pressure loop natural gas pipeline test facility at Southwest Research Institute.


(Reference [10]/Springer Nature/CC BY 4.0.)

A graphic features a plot with time measured in milliseconds on the vertical axis and fibre length in meters on the horizontal axis. The data reveals two distinct sections, one labelled Rayleigh-enhanced cable and the other S M F. A series of vertical lines indicate a pattern of signal reflections or losses at varying distances along the fibre. The transition between the two segments occurs around 800 meters, demonstrating differences in behaviour or performance characteristics between the two types of fibre cables.

Figure 26.9 Power spectral density of differential amplitude traces. The gas flow-induced vibrations at fiber installation locations on the pipeline can be observed clearly for both standard SMF and Rayleigh-enhanced fiber cable.


(Reference [10]/Springer Nature/CC BY 4.0.)

An image features two graphs labelled a and b. Graph a represents a simulated leak, with the vertical axis indicating amplitude in arbitrary units, and the horizontal axis displaying time in a certain range. A noticeable drop in amplitude occurs around time 100, marked with a label Leak. Graph b illustrates a metal drop onto a pipe, also using amplitude on the vertical axis and time on the horizontal axis. A sharp spike in amplitude is evident at nearly the same 100 mark, indicated by the label Metal drop. Both graphs convey distinct amplitude responses over time.

Figure 26.10 Demodulated time-domain traces of standard SMF, Rayleigh-enhanced fiber cable, and piezoelectric vibration sensor at a fixed pressure of 1000 psi and flow rate of 5 ft/s.


(Reference [10]/Springer Nature/CC BY 4.0.)

A three-dimensional graph presents amplitude in millivolts plotted against time in milliseconds and flow rate in feet per second. The horizontal axis represents time, while the vertical axis signifies amplitude. The z-axis reflects flow rates, ranging from zero to twenty feet per second. Five distinct data lines illustrate varying flow rates, zero, five, ten, fifteen, and twenty feet per second, with the amplitude changing over time. Each curve fluctuates differently, indicating varying responses in amplitude corresponding to the specified flow rates throughout the observed time period.

Figure 26.11 Time-domain traces of Rayleigh-enhanced fiber cable at 1000 psi pressure and different gas flow rates of 5, 10, 15, and 20 ft/s.


(Reference [10]/Springer Nature/CC BY 4.0.)

An image consists of two graphs labelled a and b. Graph a presents data from a simulated leak, with the horizontal axis representing time in milliseconds and the vertical axis indicating amplitude in arbitrary units. A marked point identifies the leak at approximately 100 milliseconds, where a notable drop in amplitude occurs. In graph b, data illustrates a metal drop on a pipe, featuring a sharp spike in amplitude at around 100 milliseconds, labelled as Metal drop. Both graphs capture distinct transient events related to different phenomena.

Figure 26.12 The time domain signals from Rayleigh-enhanced fiber during (a) control valve leak, and (b) metal drop on a pipeline.


(Reference [10]/Springer Nature/CC BY 4.0.)


Figure 26.11 shows that the recorded vibration amplitude fluctuations increase with an increase in flow rate. Ten Φ-OTDR measurements were obtained at each flow rate, and the average root mean square (RMS) amplitude was computed and fitted to a second-order polynomial curve, as shown in Figure 26.11 inset. There is a clear quadratic trend (R2 = 0.99) between the flow rate in the pipeline system and the measured vibration RMS amplitude. Furthermore, pipeline leak detection and third-party intrusion monitoring are highly desirable and help prevent pipeline damage and catastrophic failures. Therefore, we demonstrated gas leak detection by opening a control valve at one of the flanges (shown in Figure 26.8c; the leak location is ∼4 m away from the installed fiber sensors), leading to rapid de-pressurization of the pipeline with a distinct vibration signature. A measured time-domain trace using the Φ-OTDR system is displayed in Figure 26.12a, indicating a significant vibration amplitude caused by instantaneous gas leaking. The sensing fiber recorded different vibrations with a higher amplitude level, which are attributed to the propagation of leak-induced vibrations down the pipeline. Following the discovery of the leak, the flow rate was restored to 5 ft/s at 1000 psi. One meter away from the installed fiber sensors, a small metal bolt was thrown onto the pipe to show third-party intrusion detection. Extrinsic acoustic signals were produced by the metal drop and traveled through the pipe. The measured time-domain trace, which is depicted in Figure 26.12b, indicates the source of the strong amplitude peak in the pipe disturbance.


26.4 Distributed Chemical Sensing for Corrosion and Corrosivity Monitoring


The distributed fiber sensors above measure physical parameters (e.g., temperature, strain, acoustic waves, and leak vibration), which can be used to measure corrosion and pipeline failures through consequences of corrosion; however, it would be more proactive to monitor corrosion inside and outside the pipelines and detect early corrosion onset before significant mass loss and structural integrity are compromised [8].


Distributed chemical sensing (DCS) is less mature compared to DTS, DSS, and DAS but shows promising potential to monitor chemical and corrosive environments before or upon early corrosion onset to mitigate risks associated with corrosion. The chemical sensitivity of optical fiber sensors is often enabled by functional chemical sensing coatings mostly on the fiber core or cladding, such as metallic films [23], oxides [24], polymers [25], nanomaterials [26], and metal-organic frameworks (MOF) [27]. Figure 26.13 illustrates one example of the evanescent field-based chemical sensor [28]. To allow proper light interaction with the chemical sensing layers on the core or cladding, the optical fibers can be modified or manipulated via etching, tapering, or side-polishing [29]. In addition, microstructured optical fibers provide a new type of fiber structure with great potential for DCS since its inception in the 1990s [30]. These fibers are often featured with air holes running parallel to the longitudinal axis along the entire fiber length, and one of them is photonic crystal fibers (PCFs) with the air holes periodically arranged in the cladding matrix. Hollow-core PCF and index-guided PCF sensors could detect gases such as methane, H2S, CO2, and acetylene with high sensitivity (ppm level) through direct interaction of light with gases in the holes [31, 32]. The use of PCF LPG sensors have been studied for Cl and humidity monitoring [33]. More sensing applications can be found in [3436]. Although microstructured fibers offer high sensitivity and flexible designs, mass production and commercialization are still limited due to the cost of the fibers.

A diagram illustrates a fibre optic setup containing a core and cladding. At the centre, an indicator molecule interacts with the evanescent field surrounding it. The core facilitates the transmission of light, while the cladding surrounds it, preventing loss of signal. An excitation source initiates light transmission. Transmission attenuation occurs, representing signal loss as light travels through the optical fibre. The dashed circle highlights the area of interaction between the evanescent field and the indicator molecule within the cladding.

Figure 26.13 Schematic of evanescent field-based chemical sensor with a colorimetric indicator contained in the cladding of optical fiber.


(Reference [28]/with permission of Elsevier.)


DCS for corrosion monitoring can be generally fit into two categories: direct corrosion monitoring and indirect corrosive environment monitoring. For direct corrosion monitoring, metallic coatings were integrated with the distributed FOS platform to monitor corrosion directly as a distributed optical “corrosion coupon.” The corrosion-proxy distributed FOS is envisioned to be installed along the pipelines to monitor internal and/or external corrosion. Metallic film-coated optical fibers have been demonstrated for distributed monitoring of corrosion when interrogated using OFDR. As shown in Figure 26.14, mass loss of the metallic coating is monitored via spatially distributed measurements of (1) optical power intensity change [8] or (2) strain change along the optical fiber [23]. The power intensity increases in the corroded region because the light absorption of metallic film decreases as the film becomes thinner. The increase in strain is caused by release of the compressive internal stress induced by electroless deposition of Ni film. Both sensing mechanisms allow for spatially distributed corrosion monitoring, while the intensity-based sensing is subject to higher light attenuation along the fiber and needs to boost the light along the fiber for a longer distance. The distributed humidity/water and corrosion sensing experiments using internal fiber deployment and an OFDR system were carried out at the same testing site as DAS, and comprehensive findings are available in reference [37].


Corrosive environments such as pH, water content/humidity, electrolyte conductivity, and acidic gas CO2 or H2S are critical factors for corrosion and can determine the environmental corrosivity for indirect corrosion monitoring. Although DCS has only been demonstrated in fewer cases, there have been studies and development of chemical sensing materials for a broader group of FOSs, which can be potentially adopted for DCS to monitor corrosive environmental factors. For example, there are various pH sensing materials for integration with FOS, including localized surface plasmon resonance (LSPR) Au or Ag nanoparticles (NPs) incorporated composites [38], organic dyes [39], fluorescent molecules [40], polymers [41], pH-sensitive hydrogel [42], etc. Optical fiber pH sensors and pH sensitive materials are reviewed in more detail in [43].


Water and salinity as prerequisite conditions for corrosion can also be monitored by FOS. A fully distributed water sensor was demonstrated using optical backscatter reflectometry (OBR) based on the hygroscopic property of the intrinsic polymer jacket of a commercial SMF. Water absorption into the polymer jacket caused swelling-induced strain changes on the fiber which were spatially interrogated using OBR (Figure 26.15) [44, 45]. The water drops on the fiber were accurately monitored in real time along with the water drop size. The coatings of graphene oxide film and polymers (e.g., polyimide) have also been studied for water or humidity monitoring [46]. Cl and salinity can also be monitored based on the refractive index changes detected using tapered optical fiber, U-shaped fiber, SPR coating, or fluorescence sensitive material for chloride [47].

An image presents two graphs labelled a and b with multiple data lines plotted against a length axis. Graph a illustrates amplitude measured along a length of 5.25 to 5.50 meters, with different line thicknesses indicating time intervals from 0 to 35 minutes. An inset highlights a structural illustration related to corrosion. Graph b highlights micro strain along a length of 4.40 to 4.70 meters, featuring data lines for time intervals ranging from 0 to 180 minutes. Another inset focuses on a structural diagram addressing corrosion effects.

Figure 26.14 Metallic film coated FOS for distributed corrosion sensing interrogated using Optical Backscatter Reflectometry (OBR): (a) Rayleigh backscattered light increases as corrosion of Fe proceeds.


(Reference [8]/MDPI/CC BY 4.0.)


(b) Microstrain on the fiber increases with mass loss of coated Ni film.


(Reference [23]/NACE International.)


Note: 1—single-mode fiber core; 2—cladding; 3—polymer jacket; 4—coated metallic film; 5—multimode fiber core.

A graph presents a plot of micro strain against length in meters. The horizontal axis ranges from 1.70 to 1.95 meters, while the vertical axis measures micro strain, extending from minus 20 to 80. Several curves represent different time intervals, with the first water drop indicated by an arrow near 30 minutes and the second water drop marked by another arrow. The time intervals are illustrated through varying line styles, starting with 0 minutes as a dashed line and progressing through solid lines for later intervals, including 1, 2, 3, 8, 23, 30, 33, 42, 51, 69, and 80 minutes.

Figure 26.15 Demonstration of distributed water detection in air based on the swelling-induced strain changes interrogated with OBR. The first water drop was added at 1 min and the second water drop was added at 30 min.


(Reference [44]/with permission of SPIE.)


For acidic gas monitoring, gas sensitive coatings, or gas absorption layers are often used to functionalize FOS and achieve acidic gas monitoring. CO2-absorbing MOFs have been studied for CO2 monitoring and demonstrated quick and reversible responses [48]. CO2 sensors also leverage pH indicators (colorimetric or fluorescent dyes) within various sensing layers such as silica gel coating, polymer matrix with quantum dots, and sol–gel matrix with silica NPs [49]. H2S monitoring often utilizes reactive sensing materials such as Ag [50], Cu [51], ZnO [52], CuO doped SnO2, CdO, and fluorescent or luminescent indicators [53]. Table 26.2 lists some examples of FOS chemical sensing layers for corrosivity monitoring.


26.5 Challenges and Opportunities


DFOS is an emerging technology for pipeline monitoring with the unique advantages of spatially distributed monitoring over long-distance pipelines and increased safety with inert optical fibers compared to electrical based sensors in flammable gas environments. There are still some challenges in the broad adoption of DFOS by pipeline operators. The cost of the DFOS interrogation systems is still high ($50k–$150k) for some companies with limited resources for pipeline integrity monitoring, although the optical fiber cables are relatively cheap. Installing fiber-optic cables can be a complex process, especially for retrofitting into existing pipelines. Ensuring proper alignment, protection from external elements, and avoiding damage during installation are critical to guarantee the sensors’ effectiveness. Proper installation of fiber cable and calibration are also essential for accurate measurements. In addition, a massive amount of data is generated by fiber-optic cables over the extended pipelines; yet operators frequently lack the staff with the specific skillsets needed to analyze and turn the raw data into insights that can be put to use. Integrating DFOS systems with existing pipeline infrastructure and control systems also needs to be considered. Ensuring compatibility and seamless integration without disrupting regular operations is crucial for successful deployment. Moreover, the development of industry standards and guidelines for the deployment of FOSs in pipeline inspection has made slow progress. This standardization ensures uniformity in sensor implementation, data interpretation, and reporting, fostering greater confidence in the reliability of these technologies.


Table 26.2 Chemical Sensing Parameters and Examples of FOS Sensing Layers for Corrosion Monitoring


Source: Reference [8]/MDPI/CC BY 4.0.























































































Parameter Sensing Layer Test Condition Performance and Comments
Corrosion Fe 30 °C, 1 atm, CO2 saturated 3.5 wt% NaCl Distributed sensing, nm scale mass loss sensitivity
FeC 0.18–1.8 mol/l H2SO4 10 s of uW increase in light transmission in <10 min
Al 0.05 mol/l NaOH uW increase in light transmission in 5 min
pH Au-NP in SiO2 matrix Room temperature (RT) and 80 °C, 1 atm pH 2–12, quick response
Organic dyes in SiO2 matrix RT, 1 atma pH 3–12
Polyaniline RT, 1 atma pH 2–12, >1 month stability in air
fluorescent Poly (p-pyridinium phenylene ethynylene) RT, 1 atm pH 1–10
pH-sensitive hydrogel RT, 1 atm Wavelength 1.94 nm/pH, pH 3–10
Water Polyimide 30–50 °C, 1 atm 38.5 ± 1.9 microstrain/%Relative Humidity (RH)
Graphene oxide film 27–67 °C, 1 atm Wavelength 0.145–0.915 nm/%RH for 32–97.6% RH; Intensity 0.427 dB/% RH for 58.2–92.5% RH
Salinity or Cl SPR-based Al/TiO2 RT, 1 atma Accuracy 0.1‰ salinity
Fluorescent Lucigenin RT, 1 atma Detection limit 0.02 mol/l Cl
CO2 Zeolitic imidazolate framework-8 (ZIF-8) MOF RT, 1 atm 10 s of seconds response, Reversible, Linear calibration
Dyes (e.g., methyl red) in SiO2 gel 15–60 °C, 1 atm 2–3 s response
Fluorescent dye HPTS (1-Hydroxypyrene-3,6,8-trisulfonic acid trisodium salt) 5–35 °C, 1 atm Sol–gel matrix doped with silica particles improved sensitivity
H2S Ag layer 30 °C, 1 atm 90% transmittance drop in 15 min in 0.1 mol/l H2S solution
CdO in porous SiO2 450 °C, 1 atm 25–30 min response time for 1–100 ppm H2S, Irreversible but regenerable
SPR based Ag/NiO doped indium tin oxide (ITO) RT, 1atma 100 ppb–100 ppm H2S, sensitivity decreased with H2S concentration

a Assumed as RT and 1atm when lack of clarification on test conditions.


DFOS systems offer a great opportunity for predictive monitoring and maintenance of the entire pipeline, allowing operators to address potential issues before they escalate. This can lead to cost savings by minimizing downtime and reducing the need for emergency repairs. In addition, machine learning and artificial intelligence can play a crucial role in faster data processing speed, analyzing complex sensor data patterns, enhancing the accuracy of defect detection, and facilitating predictive maintenance strategies. Operators can gain insights into the overall health of the pipeline, allowing for strategic decision-making regarding maintenance, upgrades, and resource allocation. Emerging quantum sensing technologies show promise in enhancing the sensitivity and precision of FOSs. Quantum-enhanced measurements have the potential to detect even subtle changes in pipeline conditions, further improving the reliability of inspection and monitoring processes. As regulatory bodies recognize the benefits of distributed fiber-optic sensing in pipeline monitoring, compliance standards, and guidelines are likely to evolve, providing a framework that supports the implementation of these technologies and fosters industry-wide acceptance. The integration of FOSs with Internet of Things (IoT) platforms enables seamless data transmission, remote monitoring, and control. This connectivity enhances the efficiency of pipeline management by providing real-time insights, facilitating timely decision-making, and enabling swift responses to emerging issues.


26.6 Conclusion


Distributed FOSs have the advantages of nondestructive monitoring, in-situ distributive measurements, long reach, small size, light weight, flexibility, inherent immunity to electromagnetic interference (EMI), compatibility to optical fiber data communication systems, and improved safety in the presence of flammable gas/oil as compared to electrical based sensors. Distributed monitoring enabled by DFOS technology is particularly suitable for long-distance pipeline monitoring. DTS, DSS, and DAS have been developed and matured over the last two decades for physical parameters monitoring. The integration of distributed optical fiber sensors has proven to be a transformative approach, enabling the detection and localization of potential threats to pipeline integrity such as leaks, temperature variations, and structural deformations. As a less mature technology, DCS shows promising potential to detect early corrosion onset and monitor corrosive environments such as direct mass loss, pH, water, salinity, and acidic gases before or upon early corrosion onset to facilitate corrosion mitigation.


It is crucial to have effective deployment of sensors in the pipeline infrastructures with low-cost, long-distance, and high-spatial resolution interrogation. Furthermore, this chapter addresses the challenges associated with the implementation of distributed optical fiber sensors, providing valuable insights into ongoing research and development efforts aimed at overcoming these hurdles. The integration of distributed optical fiber sensors represents a significant leap forward in ensuring the resilience and safety of pipeline systems, fostering a future where distributed optical fiber monitoring technologies play a pivotal role in safeguarding critical pipeline infrastructure.


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May 10, 2025 | Posted by in General Engineer | Comments Off on Distributed Fiber-Optic Sensors for Pipeline Inspection and Monitoring
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