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

A method of testing integrity of pipe segment tubing, comprising:

• supplying, using a signal generator, an electrical test signal to electrically conductive material in an intermediate layer of the pipe segment tubing;
• determining, using a sensor, voltage, current, or both of an actual return signal that is returned from a return wire embedded within the pipe segment tubing in response to supply of the electrical test signal to the electrically conductive material in the pipe segment tubing;
• determining, using a control sub-system, an integrity state of the pipe segment tubing based at least in part on the voltage, the current, or both of the actual electrical return signal returned by the return wire;
• and
• in response to determining that the integrity state of the pipe segment tubing is a faulty state, determining, using the control sub-system, an expected size of a potential fault in the pipe segment tubing based at least in part on:
• an expected travel speed of electrical signals in the pipe segment tubing;
• 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 fault is not present in the pipe segment tubing 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 fault is not present in the pipe segment tubing.