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DOE OSTI2024

Sensorium: commissioning abundant sensors with augmented reality and QR codes

In the future, it will be possible to build high-quality models of building interiors based on data from a dense fleet of sensors reporting on air volumes much smaller than a room or zone. To enable such models, we are creating technologies that allow a fleet of sensors to be commissioned quickly at low cost. Our sensor commissioning process builds a 3D model of each building interior that includes sensor positions and sensor networking information such as sensor MAC addresses. It employs multiple technologies, including augmented reality, LiDAR, QR codes, and computer vision. Sensors can be commissioned at more than 10x the speed and at less than one tenth the cost of traditional approaches.

Bier, Eric A.↗

DOE OSTI2024

Laser-induced graphene gas sensors for environmental monitoring

Artemesia tridentatais a foundational plant taxon in western North America and an important medicinal plant threatened by climate change. Low-cost fabrication of sensors is critical for developing large-area sensor networks for understanding and monitoring a range of environmental conditions. However, the availability of materials and manufacturing processes is still in the early stages, limiting the capacity to develop cost-effective sensors at a large scale. In this study, we demonstrate the fabrication of low-cost flexible sensors using laser-induced graphene (LIG); a graphitic material synthesized using a 450-nm wavelength bench top laser patterned onto polyimide substrates. We demonstrate the effect of the intensity and focus of the incident beam on the morphology and electrical properties of the synthesized material. Raman analyses of the synthesized LIG show a defect-rich graphene with a crystallite size in the tens of nanometers. This shows that the high level of disorder within the LIG structure, along with the porous nature of the material provide a good surface for gas adsorption. The initial characterization of the material has shown an analyte response represented by a change in resistance of up to 5% in the presence of volatile organic compounds (VOCs) that are emitted and detected byArtemisiaspecies. Bend testing up to 100 cycles provides evidence that these sensors will remain resilient when deployed across the landscapes to assess VOC signaling in plant communities. The versatile low-cost laser writing technique highlights the promise of low-cost and scalable fabrication of LIG sensors for gas sensor monitoring.

Chemistry↗

DOE OSTI2025

Sizing Accuracy of Low-Cost Optical Particle Sensors Under Controlled Laboratory Conditions

Low-cost particulate matter sensors have seen increased use for monitoring at personal and local levels due to their affordability, ease of operation, and high time resolution. However, the quality of data reported by these sensors can be questionable, and a thorough evaluation of their performance is necessary. This study evaluated the particle sizing accuracy of several commonly used optical sensors, including the Alphasense optical particle counter (OPC), TSI DustTrak DRX aerosol monitor, Plantower PMS5003 sensor, and Sensirion SPS30 sensor, using laboratory-generated monodisperse particles. The OPC and DRX agreed partially with reference instruments and showed promise in detecting coarse-size particles. However, the PMS5003 and SPS30 did not correctly size fine and coarse particles. Furthermore, their reported mass distributions do not directly correspond to their number distribution. Despite these limitations, field measurements involving a dust storm period showed that the SPS30 correlated reasonably well with reference instruments for both PM2.5 and PM10, though the regression slopes differed significantly. These findings underscore the need for caution when interpreting data from low-cost optical sensors, particularly for coarse particles. Recommendations for improving the performance of these sensors are also provided.

Gautam, Prakash↗

DOE OSTI2022

Resurgence of Electron Quantum Tunneling Sensors

Quantum tunneling sensors are typically ultra-sensitive devices that have been specifically designed to convert a stimulus into an electronic signal using the wondrous principles of quantum mechanical tunneling. In the early 1990s, William Kaiser developed one of the first micromachined quantum tunneling sensors as part of his work with the NASA Jet Propulsion Laboratory. Since then, there have been scattered attempts at utilizing this phenomenon for the development of a variety of physical and chemical sensors. Although these devices demonstrate unique characteristics, such as high sensitivity, the principle of quantum tunneling often acts as a double-edged sword and is responsible for certain drawbacks of this sensor family. In this review, we briefly explain the underlying working principles of quantum tunneling and how they are used to design miniaturized quantum tunneling sensors. We then proceed to describe an overview of the various attempts at developing such sensors. Next, we discuss their current necessity and recent resurgence. Finally, we describe various advantages and shortcomings of these sensors and end this review with an insight into the potential of this technology and prospects.

Banerjee, Aishwaryadev↗

DOE OSTI2020

Degradability of Biodegradable Soil Moisture Sensor Components and Their Effect on Maize (Zea mays L.) Growth

Inexpensive and no-maintenance biodegradable soil moisture sensors could improve existing knowledge on spatial and temporal variability of available soil water at field-scale. Such sensors can unlock the full potential of variable-rate irrigation (VRI) systems to optimize water applications in irrigated cropping systems. The objectives of this study were to assess (i) the degradation of soil moisture sensor component materials and (ii) the effects of material degradation on maize (Zea Mays L.) growth and development. This study was conducted in a greenhouse at Colorado State University, Colorado, USA, by planting maize seeds in pots filled with three growing media (field soil, silica sand, and Promix commercial potting media). The degradation rate of five candidate sensor materials (three blends of beeswax and soy wax, balsa wood, and PHBV (poly(3-hydroxybutyrate-co-3-hydroxyvalerate))) was assessed by harvesting sensor materials at four maize growth stages (30, 60, 90, and 120 days after transplanting). All materials under consideration showed stability in terms of mass and dimension except PHBV. PHBV was degraded entirely within 30 days in soil and Promix, and within 60 days in sand. Balsa wood did now show any significant reduction in mass and dimensions in all growth media. Similarly, there was no significant mass loss across wax blends (p = 0.05) at any growth stage, with a few exceptions. Among the wax blends, 3:1 (beeswax:soy wax) was the most stable blend in terms of mass and dimension with no surface cracks, making it a suitable encapsulant for soil sensor. All materials under consideration did not have any significant effect on maize growth (dry biomass, green biomass, and height) as compared to control plants. These results indicated that 3:1 beeswax:soy wax blend, PHBV, and balsa wood could be suitable candidates for various components of biodegradable soil moisture sensors.

Dahal, Subash (ORCID:0000000205489103)↗

DOE OSTI2023

Ratiometric vapor sensor

A ratiometric vapor sensor is described that includes a first sensor and a second sensor. The first sensor includes a first semiconductor component comprising a vapor-sensitive semiconducting organic compound, while the second sensor includes a second semiconductor component comprising a modified vapor-sensitive semiconducting organic compound including a modifying organic group. The ratiometric vapor sensor can be used to detect the presence of a vapor such as nitrogen dioxide, and determine the concentration of the vapor by comparing the outputs of electrodes connected to the first and second sensor.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Gas sensor system

A gas sensing tube includes an outer surface, and an inner surface defining a passage. A sensor node is arranged along the sensing tube. The sensor node includes an inlet fluidically connected to the passage, an outlet fluidically connected to the passage, and an interior chamber arranged between the inlet and the outlet. A sensor cable extends along the sensing tube. The sensor cable includes a first conduit having a first connector coupled to the sensor node at the inlet and a second conduit having a second connector connected to the sensor node at the outlet. The sensor cable has a first conductor extending through the first conduit and being coupled to the first connector and a second conductor extending through the second conduit and being coupled to the second connector.

Challener, William Albert↗

DOE OSTI2023

Anomalous behavior detection by an artificial intelligence-enabled system with multiple correlated sensors

Multi-metric artificial intelligence (AI)/machine learning (ML) models for detection of anomalous behavior of a machine/system are disclosed. The multi-metric AI/ML models are configured to detect anomalous behavior of systems having multiple sensors that measure correlated sensor metrics such as coolant distribution units (CDUs). The multi-metric AI/ML models perform the anomalous system behavior detection in a manner that enables both a reduction in the amount of sensor instrumentation needed to monitor the system's operational behavior as well as a corresponding reduction in the complexity of the firmware that controls the sensor instrumentation. As such, AI-enabled systems and corresponding methods for anomalous behavior detection disclosed herein offer a technical solution to the technical problem of increased failure rates of existing multi-sensor systems, which is caused by the presence of redundant sensor instrumentation that necessitates complex firmware for controlling the sensor instrumentation.

Serebryakov, Sergey↗

DOE OSTI2024

Characterization of Intrinsic Fiber Optic Temperature Sensors by In-core and Furnace Testing

Increased research and development in nuclear technology has raised the demand for novel sensors and instrumentation to meet data objectives, and survive in different conditions and environments, beyond conventional light water reactor (LWR) environments. Expediting the deployment of advanced nuclear technologies by developing, demonstrating, and qualifying advanced reactor fuel forms necessitates a deeper understanding of how irradiation affects fuels and materials' performance. To achieve a more comprehensive understanding of fuels and materials performance, researchers require more specialized experiments and measurements. The demand for innovative sensors to support nuclear fuel development arises from the complexity of materials' behavior under irradiation and the challenges of deploying instrumentation in Material Test Reactors (MTRs) for irradiation tests. Additionally, measurements of material properties require integrated measurement systems to characterize thermal properties, mechanical properties, chemistry, and microstructure [1]. Among the potential measurement techniques, optical fiber-based sensors have been identified as potential sensors to measure different physical phenomena such as temperature, strain, pressure, and fluid level. Optical fiber sensors have the capability to provide multi-sensing and multiplexing instrumentation, allowing the measurement of different physical parameters within a single sensor configuration, and transmitting data collected at multiple locations through a single fiber. They offer immunity to electromagnetic interference, electrical passivity, compatibility with various sensing methodologies, and cost-effectiveness. Beyond their widespread use in telecommunications, silica fiber-based instruments are utilized in industrial applications, even at temperatures reaching 300?400°C, such as distributed temperature sensing in oil and gas recovery. The Department of Energy (DOE) is interested in using fiber optics to support fuel cycle development [2]. Fiber optics are an excellent candidate for harsh environment sensing, including sensing at very high temperatures (1900oC for sapphire optical fibers). Distributed fiber optic sensing has been deployed in other harsh environments like coal gasification plants [3]. Distributed strain sensing, which operates similarly to distributed temperature sensing, has been deployed to monitor underground mines and fibers have been imbedded in soil to monitor sink-hole development [4][5]. The application of fiber optic sensors to advanced reactor development is a promising area of research.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Distributed Coaxial Cable Sensors for In-Situ Condition Based Monitoring of Coal-Fired Boiler Tubes

The increasing contributions of renewable energy sources present new challenges to the operation and maintenance of the existing coal-fired power plants. One of the major operational risks is the unexpected failure of superheater boiler tubes, leading to the most unplanned power plant outrages. The boiler tube failure is difficult to predict due to the harsh operating environments. Therefore, condition-based monitoring (CBM) with a reliable high temperature sensor becomes necessary to produce a meaningful assessment of the health condition of boiler tubes and their remaining lifetime. In this work, the stainless-steel and quartz coaxial cable sensor (SSQ-CCS) is proposed for in-situ distributed monitoring of the boiler tube temperatures in existing coal-fired power plants. Comprehensive tests have been conducted with an in-house testing facility at Clemson University to study and evaluate the sensors’ performance in the temperature range of 100℃ to 600℃. The results indicated that the measurement resolution of the SSQ-CCS sensor is better than 1℃, and the drift is less than 2% over long-period testing. Meanwhile, multi-physics finite element analysis has been conducted to optimize the design and evaluate the safety of the SSQ-CCS temperature sensor under various operational conditions. Based on the performance obtained in the laboratory-scale testing, a field test has been implemented at a power plant. Four SSQ-CCS temperature sensors were installed for in-situ monitoring of the temperatures of a power plant’s superheat tube assembles. The data acquisition system has been successfully set up and collected sensing signals for more than three months. The sensing signals have been post-processed, and the monitored temperature history through the SSQ-CCS temperature sensor has been validated and compared with the conventional high temperature thermal couple data.

Jiao, Xinyu↗

DOE OSTI2025

Passive Temperature Sensors for Nuclear Applications

In April 2007, the Department of Energy (DOE) designated the Advanced Test Reactor (ATR) a National Scientific User Facility (NSUF) to advance US leadership in nuclear science and technology. By attracting new users from universities, laboratories, and industry, this program supports basic and applied nuclear research to help address the nation's energy security needs. In support of this program, the Idaho National Laboratory (INL) established in-house capabilities to develop, fabricate, test, and qualify new and enhanced temperature sensors for irradiation testing. This effort is continuing today through the DOE?s Advanced Sensors and Instrumentation (ASI) program. Although most efforts emphasize sensors capable of providing real-time data, selected tasks have been completed to enhance passive sensors for irradiations where instrumentation leads cannot be included. These sensors include silicon carbide (SiC) monitors, melt wires and the sublime temperature monitor. SiC monitors are available to detect peak irradiation temperatures between 200°C and 800°C in reactor locations where instrumentation leads cannot be used. SiC monitors may be evaluated using specialized equipment installed at INL?s Measurement Sciences Laboratory (MSL). A melt wire inventory is also maintained at MSL. This inventory contains wires for specific use in irradiation experiments ranging in temperatures from 30°C to 1500°C. Melt wires and SiC monitors have had decades of research and application. Recent research has produced a passive monitor known as the sublime temperature monitor. This passive sensor has the capability of recording temperature gradients. This paper will discuss passive temperature sensors currently being researched and implemented under the ASI program.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Laboratory testing methods to evaluate the reliability of occupancy sensors for commercial building applications

The energy performance of commercial buildings is greatly influenced by occupants which are highly variable and among the most unpredictable components of a building's operation. While most building control systems use fixed, predetermined occupancy schedules, these fixed occupancy levels can be quite different from actual occupancy. This can cause unnecessary energy consumption, particularly from heating, ventilation, and air conditioning (HVAC) and lighting systems which are responsible for approximately 60% of commercial buildings' energy use. The use of occupancy counting sensor systems integrated with building management system controls is one method that can be used to improve the energy-consuming performance of buildings. However, there is no standardized universal methodology and metrics to evaluate their reliability. The aim of this research is to develop a uniform evaluation methodology to assess the reliability of occupancy counting sensor systems in a controlled laboratory environment. The developed testing methodology includes both “typical” scenarios representing the occupancy scenarios of a typical commercial building, and “failure” testing scenarios which represent a range of potential scenarios that may impact a sensor system's reliability. These methods were then implemented in a case study to evaluate the performance of two novel occupancy counting sensor systems (i.e., door-centric, and camera-based). Results suggest that typical testing results can be used to compare the overall performance of the occupancy counting sensor systems; however, failure testing is also important to understand the weaknesses of the sensor system in order to select the suitable one for the intended use of the commercial building. In addition, the proposed methodology includes a modified confusion matrix which enables the ability to identify if failures are caused by over or under counting occupants and to what extent this occurs over the testing period.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Characterization of a selective, zero power sensor for distributed sensing of hydrogen in energy applications

The use of hydrogen as a clean and renewable energy source is increasing rapidly for both vehicle and stationary applications. There are safety concerns for the locations in which hydrogen is made, used, and transported (i.e., pipelines and tanker trucks). Sensors are needed to comply with safety regulations and to enable a smooth and safe rollout of hydrogen as an alternative energy. However, hydrogen sensors do not yet exist that have the combined features of small size and low power for easy deployment coupled with high-volume manufacturability and low cost. This is necessary to accommodate the emerging fixed and mobile markets while retaining critical metrological metrics, including measurement range, detection limits, selectivity, fast response, stability, and long lifetime. An amperometric gas sensor for hydrogen (AGS) has been developed using an innovative manufacturing method. The sensor was designed using scalable fabrication strategies based on “Printed Electronics” (PE) methodology which are compatible with large-scale production. Prototype sensors were batch fabricated with multiple individual elements on a substrate compatible in size with a standard 8-inch wafer to enable high-volume, low-cost manufacturing, thereby leveraging PE and semiconductor fabrication infrastructure. This novel AGS was instrumented with control circuitry and evaluated for hydrogen detection in the range of 0–5000 ppmv H2 in air. Specific performance evaluations included assessment of the sensor measurement range, repeatability, and selectivity.

08 HYDROGEN↗

DOE OSTI2025

Flow Enhanced Electrochemical Sensor Performance in Complex Salt Systems

To advance MSR MC&A practices, Argonne National Laboratory developed and optimized robust flow enhanced electrochemical sensors (FEES) and multielectrode array voltammetry sensors (MAVS) which provide accurate near-real time measurements of actinides in molten salts. Flow-enhanced electrochemical sensors are installed directly into MSR flow conduits for inline salt chemistry measurement, while MAVS are deployed in quiescent salt conditions enabling online species concentration determination in stationary salt vessels. This report summarizes efforts to improve electrochemical sensor technological readiness through (1) sensor testing in complex, high concentration molten salt systems to demonstrate low uncertainty actinide measurements in MSR-representative solutions and (2) demonstrations of sensor performance in challenging real-world conditions in collaboration with partner MSR institutions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Leveraging Optimal Sparse Sensor Placement to Aggregate a Network of Digital Twins for Nuclear Subsystems

Nuclear power plants (NPPs) require continuous monitoring of various systems, structures, and components to ensure safe and efficient operations. The critical safety testing of new fuel compositions and the analysis of the effects of power transients on core temperatures can be achieved through modeling and simulations. They capture the dynamics of the physical phenomenon associated with failure modes and facilitate the creation of digital twins (DTs). Accurate reconstruction of fields of interest (e.g., temperature, pressure, velocity) from sensor measurements is crucial to establish a two-way communication between physical experiments and models. Sensor placement is highly constrained in most nuclear subsystems due to challenging operating conditions and inherent spatial limitations. This study develops optimized data-driven sensor placements for full-field reconstruction within reactor and steam generator subsystems of NPPs. Optimized constrained sensors reconstruct field of interest within a tri-structural isotropic (TRISO) fuel irradiation experiment, a lumped parameter model of a nuclear fuel test rod and a steam generator. The optimization procedure leverages reduced-order models of flow physics to provide a highly accurate full-field reconstruction of responses of interest, noise-induced uncertainty quantification and physically feasible sensor locations. Accurate sensor-based reconstructions establish a foundation for the digital twinning of subsystems, culminating in a comprehensive DT aggregate of an NPP.

42 ENGINEERING↗

DOE OSTI2022

A machine learning approach to water quality forecasts and sensor network expansion: Case study in the Wabash River Basin, United States

Abstract Midwestern cities require forecasts of surface nitrate loads to bring additional treatment processes online or activate alternative water supplies. Concurrently, networks of nitrate monitoring stations are being deployed in river basins, co‐locating water quality observations with established stream gauges. However, tools to evaluate the future value of expanded networks to improve water quality forecasts remains challenging. Here, we construct a synthetic data set of stream discharge and nitrate for the Wabash River Basin—one of the United States’ most nutrient polluted basins—using the established Agro‐IBIS and THMB models. Synthetic data enables rapid, unbiased and low‐cost assessment of potential sensor placements to support management objectives, such as near‐term forecasting. Using the synthetic data, we established baseline 1‐day forecasts for surface water nitrate at 12 cities in the basin using support vector machine regression (SVMR; RMSE 0.48–3.3 ppm). Next, we used the SVMRs to evaluate the improvement in forecast performance associated with deployment of additional nitrate sensors. We identified the optimal sensor placement to improve forecasts at each city, and the relative value of sensors at each candidate location. Finally, we assessed the co‐benefit realized by other cities when a sensor is deployed to optimize a forecast at one city, finding significant positive externalities in all cases. Ultimately, our study explores the potential for machine learning to make near‐term predictions and critically evaluate the improvement realized by expanding a monitoring network. While we use nitrate pollution in the Wabash River Basin as a case study, this approach could be readily applied to any problem where the future value of sensors and network design are being evaluated.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Real-Time and Online Monitoring of Glucose Contents by Using Molecular Imprinted Polymer-Based IDEs Sensor

A highly sensitive, selective, reversible, and reusable glucose sensor is developed by using molecularly imprinted polymer-based artificial receptors onto interdigital transducer. Sensor receptors were synthesized through bulk imprinting technology by using styrene as monomer, ethylene glycol dimethacrylate (EGDMA) as cross-linker, and AIBN as free radical initiator. Topography of the synthesized receptors was investigated by scanning electron microscopy (SEM). Fabricated sensor showed concentration-dependent linear and reversible response with lower limit of detection of 30 ppb and upper limit of detection ~ 500 ppm. Furthermore, newly fabricated sensor is highly selective towards its analyte of interest in the presence of other competing agents, and the regeneration of sensor response has been assessed with the percentage error of less than 2% under the period of 1 year at room temperature and pressure conditions. The reported sensor may have potential technological applications in the field of medical diagnostics, food, and pharmaceutical industry.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

A propagation-based fault detection and discrimination method and the optimization of sensor deployment

Industrial processes can be affected by faults having a serious impact on operation when not promptly detected and diagnosed. Here in this paper, a propagation-based fault detection and discrimination(PFDD) method is proposed to develop a strategy for fault diagnosis while in the design phase of a system. The PFDD method constructs the system model using the Integrated System Fault Analysis(ISFA) technique. Based on the system model, the propagation of hardware and software faults are simulated qualitatively. Given the results of the simulation, the process by which a fault propagates can be characterized using the qualitative features of system variables including the deviation of the system variables from their expected values, the variation of the system variables over time, and the order in which each variable is influenced during the propagation of the fault. The strategy by which a fault can be detected and discriminated is defined using those features. The PFDD method supports the detection and discrimination of faults in both steady states and transient states. Based on the PFDD method, the optimization of sensor deployment in a system is discussed. A brute force algorithm is developed to examine the system’s capability at diagnosing faults and the cost of sensor deployment for all possible configurations of sensors. The optimal sensor deployment strategy can be derived accordingly. However, the brute force method is only applicable to small-scale systems due to its high computational cost. A genetic algorithm is used to optimize sensor deployment in large-scale systems. The PFDD and sensor deployment optimization methods are applied to the Experimental Breeder Reactor II (EBR-II) for verification.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗