Embedded return wire time domain reflectometry pipeline fault detection systems and methods

1. A testing system comprising:

a pipe segment, wherein the pipe segment comprises:

tubing having an inner layer that defines a pipe bore, an intermediate layer comprising electrically conductive material implemented around the inner layer to define a fluid conduit, and an outer layer implemented around the intermediate layer; and

a return wire embedded within the tubing of the pipe segment;

a signal generator electrically coupled to the electrically conductive material in the intermediate layer of the tubing, wherein the signal generator is configured to supply an electrical test signal to the electrically conductive material in the tubing of the pipe segment;

a sensor electrically coupled to the return wire embedded within the tubing of the pipe segment, wherein the sensor is configured to determine voltage, current, or both of an actual electrical return signal received from the return wire embedded within the tubing of the pipe segment in response to supply of the electrical test signal to the electrically conductive material in the intermediate layer of the tubing; and

a control sub-system communicatively coupled to the signal generator and the sensor, wherein the control sub-system is configured to:

determine an integrity state of a pipeline in which the pipe segment is deployed based at least in part on the voltage, the current, or both of the actual electrical return signal received from the return wire embedded within the tubing of the pipe segment; and

when the integrity state of the pipeline is a faulty state, determine an expected size of a potential pipeline fault in the pipe segment based at least in part on one or more expected travel speeds of electrical signals in the pipe segment and a first duration the voltage of the actual electrical return signal is less than voltage of a non-faulty electrical return signal that is expected to be returned in response to supply of the electrical test signal when a pipeline fault is not present in the pipeline or a second duration the current of the actual electrical return signal is less than current of the non-faulty electrical return signal that is expected to be returned in response to supply of the electrical test signal when a pipeline fault is not present in the pipeline.

2. The testing system of claim 1 , comprising:

a fluid pump communicatively coupled to the control sub-system and fluidly coupled to the fluid conduit defined in the intermediate layer of the tubing, wherein the fluid pump is configured to supply a test fluid to the fluid conduit defined in the intermediate layer of the tubing; and

another sensor communicatively coupled to the control sub-system and fluidly coupled to the fluid conduit defined in the intermediate layer of the tubing, wherein:

the other sensor is configured to determine a fluid parameter in the fluid conduit defined in the intermediate layer of the tubing in response to supply of the test fluid to the fluid conduit defined in the intermediate layer of the tubing; and

the control sub-system is configured to determine another integrity state of the pipe segment based at least in part on the fluid parameter in the fluid conduit defined in the intermediate layer of the tubing.

3. The testing system of claim 2 , wherein the control sub-system is configured to:

determine the other integrity state of the pipe segment based at least in part on the fluid parameter in the fluid conduit defined in the intermediate layer of the tubing while the pipe segment is not being used to transport fluid in the pipeline; and

determine the integrity state of the pipeline based at least in part on the voltage, the current, or both of the actual electrical return signal received from the return wire embedded within the tubing of the pipe segment while the pipe segment is being used to transport fluid in the pipeline.

4. The testing system of claim 1 , wherein the return wire is embedded within the fluid conduit defined in the intermediate layer of the tubing such that the return wire is in a same layer of the pipe segment as the electrically conductive material.

5. The testing system of claim 1 , wherein the return wire is embedded within the tubing of the pipe segment with a helical shape.

6. The testing system of claim 1 , wherein the control sub-system is configured to:

determine that the integrity state of the pipeline is a non-faulty state when the voltage and the current of the actual electrical return signal do not drop below the voltage and the current of the non-faulty electrical return signal by more than an error threshold that facilitates accounting for measurement error; and

determine that the integrity state of the pipeline is the faulty state when the voltage or the current of the actual electrical return signal drops below the voltage or the current of the non-faulty electrical return signal by more than the error threshold.

7. The testing system of claim 6 , wherein, when the integrity state of the pipeline is the faulty state, the control sub-system is configured to:

determine a peak negative deviation time at which the voltage of the actual electrical return signal is a largest amount less than the voltage of the non-faulty electrical return signal or the current of the actual electrical return signal is a largest amount less than the current of the non-faulty electrical return signal;

determine a transmission-to-peak negative deviation duration based on a duration between a transmission time of the electrical test signal and the peak negative deviation time; and

determine an expected location of the potential pipeline fault in the pipe segment based at least in part on the one or more expected travel speeds of electrical signals in the pipe segment and the transmission-to-peak negative deviation duration.

8. The testing system of claim 1 , wherein the tubing of the pipe segment is implemented at least in part by:

helically wrapping the electrically conductive material directly on the inner layer of the tubing to facilitate implementing the intermediate layer of the tubing; and

helically wrapping the return wire directly on the inner layer of the tubing to facilitate embedding the return wire within the tubing of the pipe segment.