Executive SummaryThis report summarizes technical progress during the program "Optical Fiber High Temperature Sensor Instrumentation for Energy Intensive Industries", performed by the Center for Photonics Technology of the Bradley Department of Electrical and Computer Engineering at Virginia Tech. The objective of this program was to use technology recently invented at Virginia Tech to develop and demonstrate the application of self-calibrating optical fiber temperature and pressure sensors to several key energy-intensive industries where conventional, commercially available sensors exhibit greatly abbreviated lifetimes due primarily to environmental degradation.A number of significant technologies were developed under this program, including• a laser bonded silica high temperature fiber sensor with a high temperature capability up to 700°C and a frequency response up to 150 kHz,• the world's smallest fiber Fabry-Perot high temperature pressure sensor (125 x 20 μm) with 700°C capability,• UV-induced intrinsic Fabry-Perot interferometric sensors for distributed measurement,• a single crystal sapphire fiber-based sensor with a temperature capability up to 1600°C.These technologies have been well demonstrated and laboratory tested. Our work plan included conducting major field tests of these technologies at EPRI, Corning, Pratt & Whitney, and Global Energy; field validation of the technology is critical to ensuring its usefulness to U.S. industries. Unfortunately, due to budget cuts, DOE was unable to follow through with its funding commitment to support Energy Efficiency Science Initiative projects and this final phase was eliminated. Accomplishments during the program are summarized briefly here and described in detail in the remainder of the report.→ A cleanroom facility was designed and installed at the Center for Photonics Technology for the fabrication of diaphragm-based Fabry-Perot sensors.→ Sensor testing methods have been developed and effectively utilized to analyze various aspects of sensor performance. A high temperature, high pressure dynamic test system was designed and assembled to allow sensor evaluation at temperature up to 1200 °C, background pressure up to 200 psi, and dynamic pressure more than 140 dB with a frequency of 47 kHz → Borosilicate ring-based engine sensors were designed and fabricated, and their performance characteristics evaluated.→ Photolithography procedures were optimized for etched diaphragm-based sensor fabrication.→ Direct bonding, hydroxide catalysis bonding, and sol-gel-based bonding techniques were investigated for diaphragm/ferrule bonding requirements.
Optical Fiber Sensors for Energy Intensive Industries iv→ Laser bonding-based pressure sensors were successfully demonstrated up to 1800 psi.→ A novel demodulation technique was developed, called grating-assisted operating point tuning (GA-OPT), by using a diffraction grating with feedback control. The GA-OPT features dynamic operating-point control, high frequency response, insensitivity to light source fluctuation, and r...