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All sourcesNASA NTRSDOE OSTI
NASA NTRS2022

Surface Biology and Geology (SBG) Thermal Infrared (TIR) Free -Flyer Concept

Scientists and engineers from the United States and Italy are developing a thermal infrared (TIR) free-flyer concept that forms an essential element of the NASA Surface Biology & Geology (SBG) designated observable and the greater NASA Earth System Observatory (ESO), which also includes observations of aerosols, clouds, convection, and precipitation; mass change; and surface deformation & change.In response to the recommendations from the 2017 National Academies decadal survey for Earth science, NASA initiated the SBG designated observable with five key research and applications focus areas: ecosystems and natural resources, hydrology, weather, climate, and solid Earth. SBG includes spaceborne measurements of hyperspectral imagery in the visible to shortwave infrared (0.4-2.5 um) and multispectral imagery in the mid and thermal infrared (3-12 um) that provide the remote sensing data needed to inform each research and applications area. High-level TIR data products include Earth surface temperature & emissivity, evapotranspiration, substrate composition, volcanic plumes, and high-temperature features. While the science, applications, and technology build on prior mission studies conducted for more than a decade, it has only been recently that a joint team of scientists and engineers from the NASA Jet Propulsion Laboratory (JPL), Agenzia Spaziale Italiana (ASI), Istituto Nazionale Geofisica e Volcanologia (INGV), and the Istituto Nazionale Astrofisica (INAF) have developed a compelling concept for a TIR free-flyer. In this concept, the TIR instrument is an eight-band radiometer. Seven of the bands are between 3 and 12 um with an additional band at 1.65 um. The instrument’s 68.8 deg total viewing angle and the free-flyer’s 665 km operational altitude results in a ground sampling distance (GSD) of <60 m at nadir, produces a swath width of 935 km, and allows for a 2-3-day revisit time. A two-band visible and near infrared (VNIR) camera, with <30 m GSD at nadir and 935 km swath width, will complement the TIR instrument. VNIR high-level data products include top & bottom of atmosphere reflectance and normalized difference vegetation indices (NDVI). The TIR instrument and VNIR camera will be mounted on a PLATiNO+ spacecraft, a multi-application, reconfigurable, and scalable platform. The launcher selected for the TIR free-flyer is the VEGA-C. To maximize the science and applications benefits the SBG-TIR free-flyer team are collaborating with personnel from the ESA Land Surface Temperature Monitoring mission (LSTM) as well individuals from the Thermal Infrared Imaging Satellite for High-resolution Natural resource Assessment (TRISHNA), a joint mission by CNES and ISRO. Pre-Phase A concept studies for the SBG-TIR free-flyer commenced in the spring 2021. This allows for the concept to be refined; for technical risks to be identified and mitigated, as necessary; and strategies for reducing the development schedule to be defined and assessed before conducting a NASA-ASI Mission Concept Review (MCR) in the spring of 2022 and a NASA Key Decision Point-A (KDP-A) as early as the summer of 2022. These are key milestones in being able to launch and begin operating the SBG-TIR free-flyer in the second half of the decade, so that many of the questions posed by the National Academies in the 2017 decadal survey can be answered.

Fabrizia-Buongiorno, Maria↗
DOE OSTI2023

Phosphor thermometry device for synchronized acquisition of luminescence lifetime decay and intensity on thermal barrier coatings

A phosphor thermometry device includes a laser that generates a laser pulse onto a thermal barrier coating (TBC) applied onto a substrate. A metallic bond coat layer is on the substrate. A ceramic top coat layer is on the bond coat layer and includes an undoped layer and a doped sensing layer having co-doped first and second rare-earth luminescent dopants that emit respective first and second different emission wavelengths upon excitation by the laser pulse. A detector receives reflected, convoluted luminescence signals from the TBC. First and second photomultiplier devices detect respective first and second different emission wavelengths of the convoluted luminescence signals. A controller receives and processes signals generated from respective first and second photomultiplier devices and determines luminescence lifetime decay and intensity variations for each of the respective first and second rare-earth luminescent dopants for temperature monitoring of the TBC.

Fouliard, Quentin↗
DOE OSTI2024

Silicon Carbide Passive Temperature Sensors at INL

Discuss the SiC passive thermometry methods currently performed at INL and ORNL, decide on best path forward for establishing an ASTM Standard for processing SiC temperature monitors, and expand this ASTM benchmarking efforts to international collaborators (Netherlands, Canada, and Poland).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Hydrogen Recombiner Catalyst Evaluations for Waste Storage

Radiolysis of water in nuclear waste storage generates hydrogen gas that can accumulate within sludge style waste and be rapidly released during agitation events, creating a significant flammability hazard. Engineering controls are therefore required to limit hydrogen concentrations during both quiescent storage and transient disturbances. Catalytic recombination of hydrogen in waste storage offgas is a proven mitigation strategy, maintaining hydrogen levels below flammability limits and managing sudden concentration spikes. Conventional recombiners rely on platinum and/or palladium catalysts, with development efforts focused on extending service life, increasing active surface area, and ensuring safe deployment in radioactive environments. Savannah River National Laboratory (SRNL) is evaluating a newly developed hydrogen recombiner catalyst from Canadian Nuclear Laboratories as a cost-effective and durable alternative for nuclear waste applications. Testing was conducted in SRNL’s Shielded Cells facility, which enables reduced-scale experimental modeling under radiation fields and near-use-case conditions relevant to radioactive waste storage. Catalyst performance was evaluated using a custom offgas characterization system designed for near-zero flow conditions. The experimental apparatus consisted of a gas-tight 2.7 L PTFE vessel equipped with temperature monitoring, gas flow controls, and a variable-speed mixer to simulate sludge agitation. Offgas composition was monitored using a dedicated gas chromatograph with argon carrier gas and a krypton internal standard. Measurements were obtained for an empty vessel, the vessel containing a well characterized radioactive tank waste sample, and the same configuration with the candidate catalyst installed. Results demonstrate that the new catalyst effectively reduced hydrogen concentrations in the offgas within the constraints of the experimental design. In addition to confirming catalytic activity, the testing provided valuable insights into experimental optimization and considerations for future performance evaluations. These findings support the potential scalability of the technology and highlight its applicability to broader nuclear waste management operations, offering improved safety and reduced operational costs through enhanced catalyst durability and lower replacement frequency.

Tener, Zachary P. [Savannah River National Laborat↗
NASA NTRS2011

Polymer Electrolyte-Based Ambient Temperature Oxygen Microsensors for Environmental Monitoring

An ambient temperature oxygen microsensor, based on a Nafion polymer electrolyte, has been developed and was microfabricated using thin-film technologies. A challenge in the operation of Nafion-based sensor systems is that the conductivity of Nafion film depends on the humidity in the film. Nafion film loses conductivity when the moisture content in the film is too low, which can affect sensor operation. The advancement here is the identification of a method to retain the operation of the Nafion films in lower humidity environments. Certain salts can hold water molecules in the Nafion film structure at room temperature. By mixing salts with the Nafion solution, water molecules can be homogeneously distributed in the Nafion film increasing the film s hydration to prevent Nafion film from being dried out in low-humidity environment. The presence of organics provides extra sites in the Nafion film to promote proton (H+) mobility and thus improving Nafion film conductivity and sensor performance. The fabrication of ambient temperature oxygen microsensors includes depositing basic electrodes using noble metals, and metal oxides layer on one of the electrode as a reference electrode. The use of noble metals for electrodes is due to their strong catalytic properties for oxygen reduction. A conducting polymer Nafion, doped with water-retaining components and extra sites facilitating proton movement, was used as the electrolyte material, making the design adequate for low humidity environment applications. The Nafion solution was coated on the electrodes and air-dried. The sensor operates at room temperature in potentiometric mode, which measures voltage differences between working and reference electrodes in different gases. Repeat able responses to 21-percent oxygen in nitrogen were achieved using nitrogen as a baseline gas. Detection of oxygen from 7 to 21 percent has also been demonstrated. The room-temperature oxygen micro sensor developed has extremely low power consumption (no heating for operation, no voltage applied to the sensor, only a voltmeter is needed to measure the output), is small in size, is simple to batch-fabricate, and is high in sensor yield. It is applicable in a wide humidity range, with improved operation in low humidity after the additives were added to the Nafion film. Through further improvement and development, the sensor can be used for aerospace applications such as fuel leak detection, fire detection, and environmental monitoring.

Hunter, Gary W.↗
NASA NTRS1975

A report on the use of thermal scanner data in an operational program for monitoring apparent rooftop temperatures

CENGAS, a division of Central Telephone and Utilities Corporation in cooperation with the Remote Sensing Institute, South Dakota State University, is using airborne thermal scanner data to monitor relative rooftop temperatures. Four Nebraska communities and one South Dakota community were surveyed by the Remote Sensing Institute for CENGAS. Thermal scanner data were converted to a film format and the resultant imagery has been successfully employed by CENGAS. The program places emphasis on heat losses resulting from inadequate home insulation, offers CENGAS customers the opportunity to observe a thermogram of their rooftop, and assists homeowners in evaluating insulation needs.

Bjorklund, J.↗
NASA NTRS2026

Using Satellite Surface Temperature Data to Monitor Urban Heat Island

Exposure to heat is a growing concern nationwide. Temperatures can be elevated in cities compared to surrounding rural areas, referred to as an “urban heat island” (UHI) effect, which is intensified during heat waves. The lack of dense networks of air temperature measurements results in few studies on urban heat. Now, a vast amount of high spatial and temporal satellite data on land surface temperature is available. We identified satellite datasets with the longest surface temperature records but different spatial and temporal resolutions: Landsat (1985-current, biweekly at 60 m and 100 m spatial resolution) and the Moderate Resolution Imaging Spectroradiometer (MODIS) data from the Terra and Aqua satellites (2000-current, daily at 1 km spatial resolution). We investigated how satellites with different spatial and temporal resolutions detect UHI effects differently. We hypothesized that 1) a dataset’s spatial resolution impacts the precision of detected UHIs spatially, since high spatial resolution Landsat data better captures spatial variability in temperature, and 2) daily surface temperature data can detect temporal patterns of UHIs and heatwave frequencies. We analyzed Landsat and MODIS satellite data in the Washington, D.C. and Baltimore region. We found that Landsat describes higher spatial variability of the UHI effect than MODIS data. However, MODIS data shows more consistent seasonal surface temperature patterns than Landsat when compared to in situ air temperature measurements. MODIS data was also able to consistently measure the frequency of heat waves. This study demonstrates the value of NASA satellite data for urban heat and climate change studies.

landsat↗
DOE OSTI2023

TDD LoRa and Delta Encoding in Low-Power Networks of Environmental Sensor Arrays for Temperature and Deformation Monitoring

Abstract Densely distributed sensor networks can revolutionize environmental observations by providing real-time data with an unprecedented spatiotemporal resolution. However, field deployments often pose unique challenges in terms of power provisions and wireless connectivity. We present a framework for wirelessly connected distributed sensor arrays for near-surface temperature and/or deformation monitoring. Our research focuses on a novel time division duplex implementation of the LoRa protocol, enabling battery powered base stations and avoiding collisions within the network. In order to minimize transmissions and improve battery life throughout the network, we propose a dedicated delta encoding algorithm that utilizes the spatial and temporal similarity in the acquired data sets. We implemented the developed technologies in a AA battery powered hardware platform that can be used as a wireless data logger or base station, and we conducted an assessment of the power consumption. Without data compression, the projected battery life for a data logger is 4.74 years, and a wireless base stations can last several weeks or months depending on the amount of network traffic. The delta encoding algorithm can further improve this battery life with a factor of up to 3.50. Our results demonstrate the viability of the proposed methods for low-power environmental wireless sensor networks.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Registration and fusion of large-scale melt pool temperature and morphology monitoring data demonstrated for surface topography prediction in LPBF

In-situ monitoring technologies for laser powder bed fusion (LPBF) additive manufacturing often face one key challenge, extracting the ultrafast melt pool (MP) signatures for understanding the localized part properties. Further, the spatial information of each monitored MP signature is essential for correlating the MP – part property. This spatial information is often unavailable especially from commercial LPBF printers. Many MP monitoring methods have been reported and utilized. However, very few of these have the MP’s spatial information. To overcome this challenge, in this work we report a method for spatially registering the key MP signatures (MP intensity, temperature, and area) to the monitored print parts. The MP signatures are obtained from our coaxial high-speed single-camera based two-wavelength imaging pyrometry (STWIP) system and the MP spatial information is obtained from an off-axis camera system. A machine learning aided image analysis method is employed to retrieve the spatial distribution of MPs within the corresponding part’s coordinates system. Then, the MP signature maps (MPSMs) are reconstructed by mapping the STWIP measured MP signatures to the registered MP coordinates. Further, a long short-term memory (LSTM) neural network is developed for estimating the layer surface topography from the registered MPSMs. The obtained results indicate that the layer surface topography can be more accurately estimated by using MP temperature signature rather than MP intensity and/or area signatures as in common practice. Finally, our developed methods for MP monitoring, registration, and MP-surface topography prediction offer advanced capabilities for the online detection of process anomalies and part defects.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Riverbed Temperature and 4D ERT Monitoring Reveals Heterogenous Horizontal and Vertical Groundwater-Surface Water Exchange Flows Under Dynamic Stage Conditions

Groundwater surface water exchange plays a critical role in physical, biological, and geochemical function of coastal and riverine systems. Observing exchange flow behavior in heterogeneous systems is a primary challenge, particularly when flows are governed by dynamic river stage or tidal variations. In this paper we demonstrate a novel application of time-lapse 3D electrical resistivity tomography and temperature monitoring where an array of thermistors installed beneath a riverbed double as resistivity electrodes. We use the array to monitor stage driven exchange flows over a 6-day period in a dynamic, stage-driven high order stream. We present a method for addressing the otherwise confounding effects of the moving river-surface boundary on the raw resistivity data, thereby enabling successful tomographic imaging. Temperature time-series at each thermistor location and time-lapse 3D images of changes in bulk electrical conductivity together provide a detailed description of exchange dynamics over a 10-meter by 45-meter section of the riverbed, to a depth of approximately 5 m. Results reveal highly variable flux behavior throughout the monitoring domain including both horizontal and vertical exchange flows.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

A study of Cell Cracks Formation During Freight Shipping : Monitoring Shock and Temperature in Real-Time & Assessing Damages With Pre and Post-Transit Characterizations of PV Modules

The solar photovoltaic (PV) industry often experiences module damage during transportation. PV modules stacked horizontally and strapped on wooden pallets may develop failures impacting their efficiency (glass shattering, cracks, frame indentation, etc.), especially when modules are not packed by professionals. The appearance of failures during the shipment from one laboratory to another can be detrimental to research studies. In this study, we tested a reusable plastic pallet designed to ship modules vertically. Five technologies of commercial PV modules were shipped together from Arizona to Florida including: glass/glass bifacial modules (framed and frameless), glass/transparent backsheet bifacial modules and glass/white backsheet modules (framed). Each module technology has a different physical size. Some modules had pre-existing cell-cracks allowing for the study of cell-crack formation and propagation during shipment. Dark current-voltage (I-V), light I-V and electroluminescence characterization were performed before and after shipment. A datalogger was used to monitor shocks and ambient temperature throughout the shipment and identify when the modules were more susceptible to damage. The modules were tilted upon receipt and the pallet were damaged but with no shattered modules. Time series shock data provided by the datalogger were used to determine potential responsible events. Our results reveal a few new post-transportation cracks for some modules. Modules parameters before and after shipment are also compared regarding the module constructions and their position in the pallet.

14 SOLAR ENERGY↗
NASA NTRS2002

Optical Fiber Strain Instrumentation for High Temperature Aerospace Structural Monitoring

The objective of the program is the development and laboratory demonstration of sensors based on silica optical fibers for measurement of high temperature strain for aerospace materials evaluations. A complete fiber strain sensor system based on white-light interferometry was designed and implemented. An experiment set-up was constructed to permit testing of strain measurement up to 850 C. The strain is created by bending an alumina cantilever beam to which is the fiber sensor is attached. The strain calibration is provided by the application of known beam deflections. To ensure the high temperature operation capability of the sensor, gold-coated single-mode fiber is used. Moreover, a new method of sensor surface attachment which permits accurate sensor gage length determination is also developed. Excellent results were obtained at temperatures up to 800-850 C.

Wang, A.↗
DOE OSTI2020

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2020

Development of Miniaturized High Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2021

A. Development of Miniaturized High Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2021

Combustion Performance and Emissions Optimization through Integration of Miniaturized High Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2022

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2024

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution of wall conditions in utility boilers. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of a coal-fired utility boiler in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

42 ENGINEERING↗