Readily available temperature sensing in boilers is necessary to improve efficiencies, minimize downtime, and reduce toxic emissions for a power plant. The current techniques are typically deployed as a single-point measurement and are primarily used for detection and prevention of catastrophic events due to the harsh environment. In this work, a multi-point temperature sensor based on wavelength-multiplexed sapphire fiber Bragg gratings (SFBGs) were fabricated via the point-by-point method with a femtosecond laser. The sensor was packaged and calibrated in the lab, including thermally equilibrating at 1200 °C, followed by a 110-h, 1000 °C stability test. After laboratory testing, the sensor system was deployed in both a commercial coal-fired and a gas-fired boiler for 42 days and 48 days, respectively. The performance of the sensor was consistent during the entire test duration, over the course of which it measured temperatures up to 950 °C (with some excursions over 1000 °C), showing the survivability of the sensor in a field environment. The sensor has a demonstrated measurement range from room temperature to 1200 °C, but the maximum temperature limit is expected to be up to 1900 °C, based on previous work with other sapphire based temperature sensors.

Modern high-temperature processes such as fossil energy production, nuclear reactors, and chemical reactors lack robust, distributed sensing systems to map temperatures in these high-value harsh-environment systems. Regular silica-fiber-based distributed temperature sensing (DTS) systems usually only operate at temperatures below about 800 °C. In this paper, we present the design, implementation, and testing of a distributed ultra-high temperature sensing system using Raman scattering intensity, which operates from room temperature to above 1400 °C. Consideration is given to the impacts of thermal radiation, fluorescence, and the multimode nature of unclad single-crystal fiber to optimize the system. Results from picosecond and sub-nanosecond lasers were compared. Measurements were taken with a ~2 m sapphire optical fiber; which represents the longest commercially available length. A spatial resolution of 12.4 cm and position standard deviation of 0.28 mm were achieved up to the maximum testing temperature of 1400 °C, which is a new record for distributed temperature sensing systems.

The observation of single mode propagation in an air-clad single crystal sapphire optical fiber at wavelengths at and above 783 nm is presented for the first time. A high-temperature wet acid etching method was used to reduce the diameter of a 10 cm length of commercially-sourced sapphire fiber from 125 micrometers to 6.5 micrometers, and far-field imaging provided modal information at intervals as the fiber diameter decreased. Modal volume was shown to decrease with decreasing diameter, and single mode behavior was observed at the minimum diameter achieved. While weakly-guiding approximations are generally inaccurate for low modal volume optical fiber with high core-cladding refractive index disparity, consistency between these approximations and experimental results was observed when the effective numerical aperture was measured and substituted for the theoretical numerical aperture in weakly-guiding approximation calculations. With the demonstration of very low modal volume in sapphire at fiber diameters much larger than anticipated by legacy calculations, the resolution of sapphire fiber distributed sensors may be increased and other sensing schemes requiring very low modal volume, such as fiber Bragg gratings, may be realized in extreme environment applications.

Anti-Stokes Raman scattering in sapphire fiber has been observed for the first time. Temperature dependence of Raman peaks’ intensity, frequency shift, and linewidth were also measured. Three anti-Stokes Raman peaks were observed at temperatures higher than 300°C in a 0.72-m-long sapphire fiber excited by a second-harmonic Nd YAG laser. The intensity of anti-Stokes peaks are comparable to that of Stokes peaks when the temperature increases to 1033°C. We foresee the combination of sapphire fiber Stokes and anti-Stokes measurement in use as a mechanism for ultrahigh temperature sensing.

A simple, cost effective and sensitive fiber optic magnetic sensor fabricated with ferrofluid and commercially available fiber optic components is described in this paper. The system uses a ferrofluid infiltrated extrinsic Fabry-Perot interferometer (EFPI) interrogated with an infrared wavelength spectrometer to measure magnetic flux density. The entire sensing system was developed with commercially available components so it can be easily and economically reproduced in large quantities. The device was tested with two different ferrofluid types over a range of magnetic flux densities to verify performance. The sensors readily detected magnetic flux densities in the range of 0.5 mT to 12.0 mT with measurement sensitivities in the range of 0.3 to 2.3 nm/mT depending on ferrofluid type. Assuming a conservative wavelength resolution of 0.1 nm for state of the art EFPI detection abilities, the estimated achievable measurement resolution is on the order 0.04 mT. The inherent small size and basic structure complimented with the fabrication ease make it well-suited for a wide array of research, industrial, educational and military applications.

A novel multimaterial fiber optic magnetic sensing design is presented and evaluated in this letter. The multimaterial optical fiber has demonstrated $ < 0.2\ n\epsilon $ sensitivity to external magnetic fields over a 2-m gauge length. Intended for immediate use in unconventional oil and gas (UOG) and measuring while drilling (MWD), this instrument could have wide-ranging subsurface sensing applications. Composed of fused silica cladding, internally distributed ferromagnetic nickel, and a series of fiber Bragg gratings, the multimaterial structure has been consistently drawn to over 1 km of length on a fiber draw tower. Due to the consistency of manufacturability and high magnetic sensitivities over long lengths, the proposed design may be considered a competitive magnetic sensor in UOG and MWD applications.