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Reliable leak detection in pipelines using integrated DdTS

temperature and DAS acoustic fiber-optic sensor


Chaofan Wang, Michael Olson, Benjamin Sherman, Nyambuu can be further classified as temperature sensors, such as DdTS
Dorjkhand, Joseph Mehr and Dr. Shailesh Singh [4] and DTS (Distributed Temperature Sensor), and acoustic
Senstar, 12 Penns Trail, STE 200 sensors generally known as DAS. A traditional DTS measures
Newtown, PA 18940, USA temperature changes either based on Brillouin scattering or
Raman scattering. Due to weak Brillouin and Raman signals, a
traditional DTS suffers from a low temperature sensitivity (0.1
Abstract— Reliable and early detection of leaks in pipelines to 1 οC) and a long leak detection time (usually minutes).
transporting liquid or gas is highly desirable. In this work, two
DAS technologies are generally based on C-OTDR or
orthogonal technologies based on high-sensitivity fiber-optic
distributed sensing were integrated into one system and tested interferometers. Environmental effects severely limit the
for their effectiveness in actual field installations. The first practical range of any interferometer-based system since these
technology is based on temperature difference detection using disturbances accumulate over the entire range of the fiber [5].
Distributed Differential Temperature Sensor (DdTS or DDTS). Therefore, DAS systems based on interferometers cannot be
The second is based on Distributed Acoustic Sensor (DAS), which reliably used for leak detection, even for a range as short as a
uses Coherent Optical Time-Domain Reflectometry (C-OTDR). few kilometers. DAS technology based on C-OTDR can be
DdTS can almost instantaneously detect a temperature difference used to detect pipeline leaks by monitoring the broadband
in the optical fiber as low as 0.0005 οC, while C-OTDR can detect acoustic signals generated from fluid (gas or liquid) leaking
minute wide-bandwidth acoustic signals. Both technologies can
through a small orifice in a buried pipeline. Since every 10 m
detect the location of a leak to within a few meters. Experimental
results for water and nitrogen gas leaks detected by the segment of the fiber is functionally independent from other 10
integrated system are presented for two different installations in m segments, disturbances do not “accumulate” with range.
the field – one where the cable was buried directly in the soil and Therefore, a C-OTDR sensor can be used for long-range leak
another where the cable was buried in soil inside a 2” conduit for detection, typically up to 40-50 km. However, the magnitude
about 29 km. DdTS reliably detected leaks at both installations, and frequency content of the leak acoustic signal is very
while DAS detected leaks only when the cable was buried directly sensitive to the cable installation method and the local soil
in soil. Test results show that the integration of both DdTS and types and conditions.
DAS technologies can increase the probability of leak detection In this paper, we test a Senstar FP7100 series (FP7100)
and minimize false/nuisance alarms. The integrated system also
sensor that integrates both DdTS (temperature-based) and
detected third party interference (TPI), thus providing a one-
system solution for pipeline integrity monitoring and intrusion
DAS (acoustic-based) technology for buried pipeline leak
detection up to 40 km from a central location. detection. The temperature sensitivity of the DdTS sensor is at
least two orders of magnitude higher than a traditional DTS
Keywords— Leak Detection; DdTS; DTS; DAS; TPI; C-OTDR; [4]. The leak detection time of DdTS is typically a few
Oil and Gas Pipeline; Fiber Optics Sensor seconds, while it is on the order of minutes for a traditional
DTS. The acoustic sensor is based on traditional DAS
I. INTRODUCTION technology. The FP7100 sensor uses two fibers for a typical
range of 40-50 km, and, as an additional benefit, also provides
Early and accurate pipeline leak detection is essential to
protection against TPI.
help reduce negative impacts on the environment and decrease
The structure of the paper is as follows: Section II briefly
restoration cost. Typical performance criteria for leak
describes FP7100 technology. Section III describes the leak
detection systems focus on high sensitivity, reliability,
(nitrogen gas and water) test results from Site 1, where a 460
accuracy and robustness and are described in API 1155
m long cable was buried directly at a depth of ~3 ft. Section
regulation [1, 2].
IV presents leak (nitrogen gas and water) and TPI test results
Typical Internal Leak Detection methods based on
from Site 2, where a 29 km cable was buried in a conduit at a
Computational Pipeline Monitoring (CPM) include the
depth of ~5 ft. Section V discusses the test results and
Mass/Volume Balance method, Negative Pressure Wave
summarizes the performance of the FP7100 system and its
method, Statistical Analysis, and Real Time Transient Models
advantages over other leak systems. Section VI concludes the
(RTTM) [1-3]. The main drawbacks of these methods are their
paper.
low sensitivity (on the order of 1% of design throughput) and
low location accuracy (in excess of 100 m) [3]. II. TECHNOLOGY FOR LEAK AND TPI
External Leak Detection methods include visual
FP7100 integrates both DdTS and DAS technologies for
observations from vehicles or aircraft, trained dogs, and
leak detection, which can help to reduce the nuisance alarm
strategically positioned sensors based on chemical, acoustic,
rate (NAR) and increase the probability of detection (PD). The
thermal, and recently distributed fiber-optic sensing [1-3].
DAS is based on the theory of C-OTDR [5]. DdTS is based on
Fiber-optic sensors benefit from a long range and ease of
an enhanced form of C-OTDR [4]. The working principle is
installation and maintenance. Distributed fiber-optic sensors
that the phase change in the backscattered light caused by the

978-1-5386-7931-9/18/$31.00 ©2018 IEEE


change of temperature/strain in a fiber can be replicated by the A very weak leak test was conducted using nitrogen gas
change of wavelength of the interrogating light signal [4, 6]. with a leak pressure of about 50 PSI. The test configuration is
DdTS is much more sensitive (over two orders of magnitude) shown in Fig. 1. The leak lasted for ~ 5 min. Fig. 2 shows
than a traditional DTS and can measure a sub-0.0005 °C DdTS temperature rate profiles of the gas leak at distances of
temperature difference as well as track changes in temperature 1, 3 and 5 ft. Despite the low pressure, the leak was detected
over days. by DdTS from a distance of 5 ft, where the measured
temperature rate was -0.004 °C/min. The temperature first
III. FIELD TEST RESULTS FOR CABLE BURIED DIRECTLY AT SITE 1 dropped because of the Joule-Thompson effect, and increased
FP7100 was tested for leak detection performance on a back after the leak was stopped. The temperature rate was
cable buried directly in the soil at a depth of about 3 ft. The smaller at 3 ft than at 5 ft likely due to cooler ambient
length of the sensing cable was about 460 m and was buried in temperatures close to the orifice (a consequence of previous
a serpentine pattern such that its distance from the leak point leak tests) and vertical misalignment of the cable at 3ft. There
could be 1, 3, 5, and 10 ft. The leak occurred at roughly the was no discernible DAS acoustic signal (not shown)
same depth as the cable and was oriented 45 degrees relative accompanying this weak leak. This test illustrates the high
to the sensing cable, as shown in Fig. 1. sensitivity of FP7100 DdTS technology.
B. Nitrogen gas leak at 1000 PSI, 1/8” orifice, and distances
of 1, 3, and 5 ft

Fig. 1. Test configuration at the customer site 1. The nearest horizontal


distance between sensing cable and orifice was ~1 ft and the leak was oriented
45 degrees.

A. Small nitrogen gas leak at 50 PSI, 3/16” orifice and


distances of 1, 3 and 5 ft

Fig. 4. (Top) DAS waterfall at 1000 PSI. (Bottom) Spectrogram at a distance


Fig. 2. Temperature rate profiles of a 50 PSI nitrogen gas leak at distances of 1, of 1 ft.
3 and 5 ft from the orifice. No DAS signal was observed at this low pressure.
In this brief test, the leak lasted for 30 seconds. The top
graph in Fig. 3 shows the detected temperature rate profile at 1
ft and 5 ft, from which a clear temperature drop (due to the
Joule-Thomson effect) was observed. During the leak, the
measured temperature rate was -0.055 °C/min at 1 ft and -
0.018 °C/min at 5ft. A positive rate was observed after the
leak was stopped. The 1000 PSI leak created such a strong
initial signal at 1 ft that it was filtered out by the algorithm,
making it appear as though the temperature began dropping at
5 ft earlier than at 1 ft. As the bottom (waterfall) graph of Fig.
3 shows, clear DdTS temperature rate signals were observed at
1, 3 and 5 ft.
The leak was also detected by DAS at 1,3, and 5 ft, as
shown in top graph of Fig. 4. The corresponding spectrogram
(bottom graph, Fig. 4) shows a strong leak signal at 1 ft.
Fig. 3. DdTS signals of a 1000 PSI nitrogen gas leak. The top graph shows C. Water leak at 270 PSI with a 3/16” orifice and a
temperature rate profiles 1 ft (white line) and 5 ft (red line) from the orifice, temperature close to ambient
and the bottom graph shows the temperature rate waterfall. Leaks at 1, 3, and 5 A 40 s water leak test was performed at a temperature very
ft. are clearly observable with precise locations.
close to that of the top soil. The DdTS temperature rate profile
and DAS acoustic signal spectrogram 1 ft from the orifice are
shown in Fig. 5. Clear temperature change was observed with
a rate of ~0.03 °C/min (Fig. 5a). The leak acoustic signal was
clearly apparent as well (Fig. 5b).

Fig. 7. (a) DdTS temperature rate signal of a 250 PSI nitrogen gas leak (0.5,
0.5) ft above the orifice. (b) Corresponding DAS leak spectrogram.

Fig. 5. (a) Temperature rate profile of a 270 PSI water leak ~1 ft from the
orifice. The water temperature was close to the ambient temperature. (b)
Corresponding DAS leak acoustic spectrogram.

IV. FIELD TEST RESULTS FOR CABLE BURIED IN A CONDUIT AT


SITE 2
This section describes field test results from a second test
site (Site 2), at which the cable was buried in a 2” conduit next
to a pipeline. The cable was buried 2 - 4 ft deep depending on
its location. The total length of the cable was ~29 km and was
buried near both highways and audibly isolated areas.

A. Nitrogen gas leak at 250 PSI, 1/4” orifice, and a distance


of ~0.7 ft

Fig. 6. The relative location of the sensing cable to the orifice was (0.5, 0.5) ft,
with the leak directed downward (6 o’clock).

A nitrogen gas leak test was conducted at 250 PSI Fig. 8. DdTS and DAS signals of a water leak at 160 PSI, 6 GPM flow rate,
through a 1/4” orifice. The leak occurred at a depth of 3 ft, and ~50 °C above ambient for Site 2. The top graph shows the temperature rate
signal 1 ft from the leak point, the middle graph shows temperature rate
was oriented downward (6 o’clock), and lasted for 4 mins. The waterfall, and the bottom graph shows DAS signal 1 ft from the leak point
test configuration is shown in Fig. 6. The relative location of (where no acoustic signal was detected).
the buried cable to the orifice was roughly (0.5, 0.5) ft, which
means a 0.5 ft horizontal and 0.5 ft vertical offset from the Fig. 7 shows the detected DdTS temperature rate signal
orifice. In this configuration the leak was 135 degrees from and the DAS acoustic signal spectrogram. The leak-induced
the sensing cable (non-ideal for gas leak detection). temperature rate was observed to be ~ - 0.02 °C/min.
However, the DAS leak signal was weak and only present at orientations of the leaks were misaligned with the cable. Since
lower frequencies. tuning to detect leaks at low frequencies typically occupied by
environmental noise can greatly increase nuisance alarms,
B. Water leak at 160 PSI (6 GPM) with a 1/8” orifice, 1 ft
DAS may not be an effective technology for leak detection
distance, and a temperature 50 °C above ambient
when the cable is in a conduit. The high PD of 81% for the
A 160 PSI water leak was simulated in the field at a depth
FP7100-based DdTS system clearly demonstrates its high
of 3 ft with a 6 o’clock orientation and a 20 minute duration.
sensitivity.
The cable was buried 1 ft directly below the orifice. This was
the optimal configuration for water leak detection because the C. Importance of cable placement for gas and liquid leaks
leak was aimed directly at the sensing cable and gravity was Of the five missed DdTS leak alarms out of 26 leak tests at
aligned with the water flow. A large temperature rate of ~ 0.03 Site 2, three were missed due to suboptimal cable placement
°C/min was observed, as shown in Fig. 8. The location of the with respect to the leak point, one because of tuning
leak can be easily identified in the waterfall graph. Almost no parameters, and one because of a combination of a low
DAS acoustic signal was detected during the leak. pressure and a large offset. Of the three missed due to cable
placement, the first was a gas leak in which the cable was
C. TPI Detection with the cable in a conduit
placed below the leak point, and the other two were water
FP7100 provides a complete solution for pipeline leaks
leaks in which the cable was placed above the leak point.
(DdTS and DAS) and TPI in one system. The spectrogram in
Out of 26 gas and water leak tests, 23 tests occurred with
Fig. 9 shows a typical machine digging signal at Site 2.
suboptimal cable configurations, where either the cable offsets
were misaligned or the leak was orientated 135 or 180 degrees
from the cable. The fact that most of these leaks were still
detected demonstrates the high reliability of the FP7100 DdTS
even with suboptimal cable placement.
D. Temperature sensitivity requirements for reliably detecting
leaks
The high PD of the DdTS system at Site 2 depended
critically on the ability of the system to detect temperature
differences as small as 0.0005 °C. Typical changes in
temperature at the cable due to a leak were less than 0.1 °C.
Fig. 9. Spectrogram showing a machine digging signal at test site 2.
Therefore, other DTS systems, whose temperature sensitivity
is typically 0.1-1 °C, will likely not detect such leaks.

V. DISCUSSION E. Requirements for retrofitting leak sensors to existing fibers


FP7100 can be retrofitted to most existing single-mode
Several observations can be made from the test results at fibers already installed next to pipelines, either directly buried
Sites 1 and 2: or installed in a conduit, and can provide reliable and robust
A. Leak signals from cable buried directly in soil at Site 1 leak detection. To our knowledge, no other existing system
Both DdTS and DAS leak signals were strong with PD has this capability.
performances of 97% and 78%, respectively, based on 99 leak F. Importance of using two independent technologies for leak
tests. DAS acoustic signals were observed at much higher detection
frequencies than those typically occupied by environmental Since DdTS and DAS are independent technologies,
noise, which allowed for reliable detection while maintaining Senstar’s FP7100 can be used in an integrated mode using
a low NAR. DdTS alarmed for cables as far as 5 ft from the DdTS as a primary sensor and DAS as a secondary
leak at a pressure of 500 PSI, while DAS alarmed at 1 ft. (verification) sensor to greatly reduce nuisance alarms. Leak
Therefore, either DdTS or DAS can be used effectively for signals from DdTS are clearly observable for most of the leaks
leak detection at Site 1. However, a combination of both with relatively unambiguous start and end times. DAS signals,
DdTS and DAS, as in FP7100, further lowers NAR and even when weak, can usually be identified by a human
provides a robust and reliable leak detection solution. observer if the leak takes place in a quiet area away from
B. Leak signals from cable buried in a conduit at Site 2 vehicle traffic. Each method provides an independent means
DAS signals were significantly weaker at Site 2, where the of looking at the leak, and their simultaneous use has the
cable was buried in a conduit, than they were at Site 1, where potential to detect leaks under 1% of the flow rate, in seconds,
the cable was buried directly. The PD for DdTS was 81%, but with a precise location resolution of +/- 5 meters.
for DAS was 0% based on a total of 26 leak tests (20 gas and G. Possibility for verification of a leak alarm by a trained
6 water leaks) conducted over 3 months. The ineffectiveness operator
of DAS detection was likely due to two factors: (1) The To further minimize nuisance alarms, a trained operator
system was tuned to detect high frequencies characteristic of a can observe signals from both DdTS and DAS to verify an
leak, which were likely attenuated by the conduit, and (2) The alarm. This can be very effective because once a leak occurs,
Table 1. Comparison of leak detection technologies

it continues for a long enough time for a trained operator to nature, the integration of DdTS and DAS technologies can
analyze signals in real time to come to a definite conclusion. provide better PD and NAR performance than either
DdTS and DAS provide complementary insights into a technology in isolation. PD and NAR can be further improved
potential leak, and FP7100 offers various visual tools to aid an by a trained operator, who can verify leaks alarms using real-
operator in evaluating both signal types simultaneously. time visual DdTS and DAS information. In addition to leak
detection, the FP7100 system has integrated TPI technology,
H. Nuisance alarm rate
making it well-suited for long-range pipeline integrity
FP7100 was tested for NAR at Site 2 over a 29 km buried
monitoring and intrusion detection.
cable. In general, the NAR performance depends critically on
parameter settings. The NAR was measured for a leak VII. REFERENCES
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