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Gas pipeline leakage detection based on PZT sensors

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DOI: 10.1088/1361-665X/26/2/025022

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Smart Mater. Struct. 26 (2017) 025022 (7pp) doi:10.1088/1361-665X/26/2/025022

Gas pipeline leakage detection based on


PZT sensors
Junxiao Zhu1, Liang Ren2, Siu-Chun Ho1, Ziguang Jia2 and
Gangbing Song1,2
1
Department of Mechanical Engineering, University of Houston, Houston, TX, 77204, USA
2
School of Civil and Hydraulic Engineering, Dalian University of Technology, Dalian, Liaoning, 11604,
People’s Republic of China

E-mail: gsong@uh.edu

Received 31 May 2016, revised 4 August 2016


Accepted for publication 28 September 2016
Published 16 January 2017

Abstract
In this paper, an innovative method for rapid detection and location determination of pipeline
leakage utilizing lead zirconate titanate (PZT) sensors is proposed. The negative pressure wave
(NPW) is a stress wave generated by leakage in the pipeline, and propagates along the pipeline
from the leakage point to both ends. Thus the NPW is associated with hoop strain variation along
the pipe wall. PZT sensors mounted on the pipeline were used to measure the strain variation and
allowed accurate (within 2% error) and repeatable location (within 4% variance) of five manually
controlled leakage points. Experimental results have verified the effectiveness and the location
accuracy for leakage in a 55 meter long model pipeline.
Keywords: lead zirconate titanate (PZT) sensor, gas pipeline, leakage, negative pressure
wave (NPW)

(Some figures may appear in colour only in the online journal)

1. Introduction mass/volume balance [18], real time transient modeling [19–


21], pressure point analysis [22], statistical [23], digital signal
Oil and gas pipelines, which are used to transport hazardous processing [24] and negative pressure wave [25, 26].
materials across vast distances, are among the key building In this paper, lead zirconate titanate (PZT) sensors were used
blocks of the petroleum industry. With the rapid development of to detect the arrival time of negative pressure wave (NPW)
the petroleum industry in recent years, over 3600 000 km of associated with leakage in a model pipeline. As will be discussed
pipeline has been built in the US until 2014 at a rapid rate of in section 2.1, the NPW originates at the point of leakage and
more than 30 000 km each year since 2010 [1]. With increased propagates towards both the ends of the pipeline. Lead zirconate
coverage of pipelines across such long distances, the chance for titanite (PZT) is a class of smart materials which is widely used in
sustaining damage that cause leakage of the hazardous materials structural health monitoring [27–29]. An NPW sensing response
becomes proportionately larger. Based on the hazardous liquid of PZT sensor is presented in section 2.2 and the leakage location
pipeline failure data for the period 2002–2005 provided by the theory is described in section 2.3. Thereafter, the experimental
Office of Pipeline Safety (OPS), the estimated cost of each setup is described in section 3. Finally, the results, discussions
pipeline failure event is over $157 000 [2]. To minimize the and conclusion of this work are presented in sections 4–6.
potential environmental damage and economic loss, such as
products lost, property maintenance costs and recovery fees, a
method to accurately detect and locate the leak at a rapid pace is
2. Background theory
necessary and a pressing research topic.
A number of leak detection methods have been developed
2.1. Propagation mechanism of NPW in pipelines
[3], including non-technical methods [4], acoustic methods [5–
9], optical methods [10–12], cable sensors [13], soil monitoring Under the normal operating conditions of gas pipelines, the
[14], vapor sampling [15], ultrasonic flow meters [16, 17], internal pressure of the pipeline is relatively constant and

0964-1726/17/025022+07$33.00 1 © 2017 IOP Publishing Ltd Printed in the UK


Smart Mater. Struct. 26 (2017) 025022 J Zhu et al

Figure 1. NPW propagating along the pipeline. Figure 3. PZT sensor directly mounted on the pipe wall.

Figure 4. Typical charge mode amplifier circuit.

location of the PZT sensor, the decrease in internal pressure


Figure 2. Typical hoop strain variation.
leads to a decrease in pipe circumference, and thus a
corresponding decrease in hoop strain, which coincides with
significantly higher than the ambient, external pressure. When the direction of strain along the direction ‘1’, as shown in
a crack develops that exposes the inside of the pipeline, the figure 3.
internal pressure at the leakage point drops significantly as a The relation from strain to output voltage of PZT sensor
result of pipeline content, i.e. natural gas, escaping through
is given by [32]
the crack. The pipeline content moves from both upstream
and downstream simultaneously towards the leakage point. d31Ec lc bc
This flow of content generates a decompression wave (i.e. Vo = (1 - n )(leff beff ) e11. (1 )
CF
negative pressure wave) propagating through the pipeline
contents from the leakage point towards both ends of the Here n is Poisson’s ratio of the host structure material, leff is
pipeline [30], as shown in figure 1. This decrease in pressure the effective length fraction in the direction ‘1’, beff is the
inside the pipeline is accompanied by the contraction of pipe effective width fraction in direction ‘2’, d31 is the piezoelectric
wall resulting in decreasing pipe hoop (circumferential) strain coefficient relate the normal strain in the direction ‘1’ to a
[25] as shown in figure 2. The hoop strain variation on the field along the poling direction ‘3’, Ec is the Young’s mod-
pipe wall could be detected and measured by PZT sensors, ulus of the PZT material, lc is the length of the PZT sensor in
which are directly mounted on the pipeline wall. The NPW
the direction ‘1’, bc is the width of the PZT sensor in the
sensing response of PZT sensor is discussed in the following
direction ‘2’ and CF is the feedback capacitance of the charge
section.
mode amplifier circuit as shown in figure 4. From
equation (1), one can see that both lc and bc depend on the
2.2. NPW sensing response of PZT sensor geometry of the PZT sensor. With a higher value of lc, the
Piezoelectricity describes the phenomenon in which a piezo- PZT sensor will be more sensitive to the change in the hoop
electric material generates an electric field when subjected to strain; while increasing bc will increase the signal strength, the
a mechanical stress (direct effect), or, conversely, generating a increase in bc will spread the PZT sensor response over a
mechanical strain in response to an applied electric field [31]. longer time duration since the NPW will remain within the
PZT is a typical ceramic material which has noticeable area of the PZT sensor for a longer time. If the response is
piezoelectric characteristics. spread over a longer time period, the leak detection algorithm,
The PZT sensors were directly mounted on the pipe wall which tries to detect spikes in signals, will have difficulty
to detect the arrival of the NPW. When the NPW reaches the processing the prolonged signal for signs of leakage. Thus for

2
Smart Mater. Struct. 26 (2017) 025022 J Zhu et al

Figure 6. Illustration of pipeline leakage and NPW propagation.

origin, which is the leakage point. Figure 6 illustrates the


working principle of this method [34].
Referring to figure 6, the distance of the leak point to the
Figure 5. Typical responses of PZT sensors to NPW.
upstream sensor (i.e. sensor near to the entry of the pipe) is:

L + (m + V ) Dt
the purposes of leakage detection based on NPW signal, it is L 1 = (m - V ) , (2 )
better to have lc much larger than bc . 2m

To measure the NPW signals, a signal conditioning cir- where L1 denotes the distance between the upstream sensor and
cuit was introduced to process the output voltages of the PZT the leak point, L denotes the distance between the upstream and
sensors. Since the signal conditioning circuit, as shown in downstream sensors, m denotes the propagation velocity of the
figure 4, works as a band pass filter [33]; the output voltage of NPW, V denotes the contents flow velocity, and Dt = t1 - t2
PZT sensor is zero if there is no NPW wave arriving at the denotes the arrival time difference of the wave to the upstream
location of the PZT sensor. The amplitudes of NPW signals as and downstream sensors while t1 and t2 are the arrival time of the
measured by the PZT sensors are proportional to a certain PZT #1 and PZT #2, respectively. The content flow velocity V
range of high frequency components of hoop strain variation is negligible compared to the NPW velocity m and thus ignored.
as shown in (1), which can indicate the arrival time of Thus equation (2) can be rewritten as
the NPW. L + mDt
L1 = . (3 )
2
2.3. Leakage location theory
The NPW velocity μ=285.75±23.6 m s−1 was measured in
The PZT sensors are directly mounted on the pipe wall and used the same pipeline system based on fiber Bragg grating sensors
to measure the local hoop strain change. The typical response of [26], while μ=300 m s−1 was considered for use in the leakage
PZT sensors to NPW is shown in figure 5. Initially, when the location process in the following experiments. This value was
pipe is undamaged, the output amplitude is maintained at 0 V chosen as it is situated in the upper margin of the velocity
because the internal pressure is held constant under the normal estimation and for convenience of calculations.
operating conditions. Then, the downward, pulse-like waveform
indicates the arrival of the NPW to each specific sensor. The
initial downward slope of the pulse indicates the decrease of 3. Experimental setup
internal pressure associated with the NPW as it reaches PZT
sensor location, while the subsequent upslope of the pulse The model pipeline, shown in figure 7, consists of a series of
indicates the internal pressure settling at a different baseline 19.05 mm×3.048 m (3/4 in.×10 ft.) PVC Plain-End pipe
pressure. The negative peak of the waveform pinpoints the time sections connected together to form a pipeline with a total
when the NPW passes through the PZT sensor location, which is length of 55.78 m. Due to this long length, the model pipeline
chosen to define the arrival time of NPW. Finally, the circuitry was bent every 9.14 m using ten 90° elbow connectors and
used to measure signals from PZT sensor inherently forms a five 0.20 m pipe sections shown in figure 8.
band pass filter. Thus, when the internal pressure settles down, Six PZT sensors (15 mm×10 mm) were directly
low frequency signals dominate the PZT sensor signal and the mounted on the pipeline to detect NPW signal arrival (details
filtering effect of the circuitry causes the output amplitude to are shown in table 1). An NI PXI-5105 Digitizer was used as
returns to 0 V. a data acquisition system. The digitizer was triggered by the
Two of the PZT sensors can be designated for use in the voltage signal of PZT #1 with the trigger level at −0.02 V
location of the leakage point. The time difference between the and all the signals from six PZT sensors were recorded
negative peaks of the two designated PZT sensors is defined simultaneously at a sampling rate of 100 KS s−1. Five
as Dt . manually controllable leak valves were installed along the
The difference in arrival time of the NPW at the desig- pipeline (details are shown in table 2) to simulate a leakage
nated sensors can be used to estimate the location of the NPW point. An air compressor was used to pressurize the pipeline

3
Smart Mater. Struct. 26 (2017) 025022 J Zhu et al

Figure 7. Model pipeline.

Figure 8. Diagram of the model pipeline with multiple simulative leak points.

Table 1. Sensor location.


up to 20 psi for each test. Also, pressure regulator and safety
release valve were installed for safety.
PZT sensor # Location from inlet (m)
PZT #1 (P1) 1.32 3.1. Experimental procedure
PZT #2 (P2) 17.15
PZT #3 (P3) 19.98 The following steps were taken iteratively to perform the
PZT #4 (P4) 35.80 experiment:
PZT #5 (P5) 38.63
PZT #6 (P6) 54.46 1. All the controllable leakage valves and both pipeline
ends were closed for pressurization.

4
Smart Mater. Struct. 26 (2017) 025022 J Zhu et al

Table 2. Leakage location.

Leakage valve # Location from inlet (m)


Leakage #1 (L1) 6.14
Leakage #2 (L 2) 15.55
Leakage #3 (L3) 24.84
Leakage #4 (L4) 34.21
Leakage #5 (L5) 43.47

Figure 10. Leakage position determination results of L1.

Figure 9. Leakage position determination results of model pipeline


with multi leak valves.

2. An air compressor was used to pressurize the pipeline


up to 20 psi.
3. One of the leakage valves was manually opened to
simulate the leakage.
4. The data acquisition system was triggered automatically Figure 11. Leakage position determination results of L5.
by the NPW signal and recorded the signals from PZT
sensors. distance in the typical duration. In the model pipeline, PZT
5. The leakage point could be estimated by the recorded #1 and PZT #6 were in the NPW reflection range. Conse-
signals based on the leakage location method. quently, the estimated distance errors and variances of the
Leakage #1 and Leakage #5 are comparatively larger than
Leakage tests were repeated 19 times at each leakage point. the others can be explained by equation (3). Consequently,
the estimated distances of Leakage #1 based on the upstream
sensor PZT #1 were increased as shown in figure 10, while
the estimated distances of Leakage #5 based on the down-
4. Results
stream sensor PZT #6 were decreased as shown in figure 11.
The experimental results for location detection and actual
leakage positions (each line) are shown in figure 9. The
maximum error of the results was 2% of the location pre- 5. Discussions
diction based on 55 meters, the total length of the model
pipeline, while the average of the variance of each leak Previous studies have used FBGs to detect leakage [25]; but
position result was stable within 4%. in this study, PZT sensors were used to replace FBGs to
On the model pipeline the NPW propagates 15 m in detect leakage. The higher frequency, allowed by typical data
0.05 s, which is the typical duration of NPW pulse as shown acquisition system compatible with PZT sensors, allows for
in figure 5. Due to the superposition of incident and reflected higher accuracy albeit with cost and cabling constraints.
NPW, the negative peak of the pulse will be postponed if the The goal of this experiment is to assess the viability of
distance between the PZT sensor and the end of the pipeline is PZT sensors for detection of leakage in pipelines. Due to
less than 7.5 m, which is half of the NPW propagation limitations of the model pipeline, such as short length and

5
Smart Mater. Struct. 26 (2017) 025022 J Zhu et al

small diameter, several parameters are non-transferable from Subsequent studies for PZT-based leakage detection will be
experimental setup to real world applications. The differences carried out regarding the effect of pipeline design parameters,
between the experimental setup and the real world applica- such as material and wall thickness, on the capabilities of the
tions are discussed below: PZT sensing system. Pipeline damages, such as dents or
corrosion will have local effects on the pipeline structure and
• PZT sensors mounted on the pipeline should ideally have
may be detected by the PZT sensing system, and thus may be
a maximal length in lc (the direction ‘1’) and minimal
used as an early warning indicator for potential future leakage
length in bc (the direction ‘2’), as shown in figure 3.
sites. Wireless communications techniques designed for PZT
However, due to the small diameter of the model pipeline,
sensor will also be tested in order to verify applicability to
the PZT sensors were mounted on the pipeline with
long distance pipelines.
lc = 10 mm in the direction ‘1’ and bc = 15 mm in the
direction ‘2,’ as shown in figure 7, which is detrimental to
the estimated results of the leakage location. It can be
6. Conclusions
improved by choosing the appropriate size of the PZT
sensor so that lc is much longer than bc . In order to ensure
A PZT-based pipeline leakage detection and location method
a better contact of the PZT sensor with the pipeline in the
was presented in this paper. The dynamic strain variation of
lc direction, the PZT sensor can be custom-made to bend
the pipe wall introduced by the NPW was detected by mea-
along the surface of the pipeline. In the experiment
suring the time of arrival of the NPW towards PZT sensors
described in this paper, the PZT sensors were flat patches
installed along the length of the pipeline. During these tests, it
and did not conform to the curvature of the pipe
was found that the time of arrival approach allowed the
circumference, thus reducing the contact of PZT sensor
accurate and repeatable location of the leakage points, how-
along the lc direction.
ever, a challenge to be overcome is the reflection of the NPW
• The pipeline hoop stress equation [35] is expressed as
at each end of the pipeline. The reflections, as shown by the
D results, decreased the accuracy of the PZT sensors located
sh = ( pi - pe ) (4 )
2t near the ends of the pipeline. Future steps in this research are
where pi and pe are the internal and external pressure to extend the application of leakage detection method to the
respectively, D is the diameter of the pipeline and t is the liquid pipeline, broaden the application to stiffer pipeline
wall thickness. The hoop stress sh is proportional to the materials, such as steel, and improve the algorithm to sur-
internal pressure pi and the diameter of the pipeline D, mount the influence of reflection at the ends of the pipeline.
when the external pressure pe is negligible compared to
the internal pressure pi . Since the internal pressure was 20
psi and the diameter of the model pipeline was 19.05 mm, Acknowledgments
the responses of PZT sensors would have much higher
amplitudes in real world pipeline applications, as they This research was partially supported by the Major State Basic
usually have much higher internal pressures and larger Development Program of China (973 Program, grant number
diameters. The higher amplitude of response can lower 2015CB057704), Innovative research group project (grant
the data acquisition negative trigger level and tolerate number 51421064) and general projects (grant number
higher electromagnetic interference in real world 51478080 and 51278084) of Natural Science Foundation of
applications. China. Mr Jia was supported by the Chinese Scholarship
• Another major difference is the distance. Pipelines in the Council for his one-year research visit at University of Houston.
field usually carry gas/oil across miles, and hence may The authors would like to acknowledge these financial supports.
cause difficulties in receiving signals from PZT sensors
that are installed along the length of the pipeline. Since it
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