Results for “sensor” — Page 14

DOE OSTI2022

Electrochemically decorated gold nanoparticles on CVD graphene ChemFET sensor for the highly sensitive detection of As(III)

Here, in this paper, we report a novel reusable receptor-free chemically sensitive field-effect transistor (ChemFET) sensor for the sensitive detection of As(III) using electrochemical doping of Au nanoparticles (AuNPs)-chemical vapour deposition (CVD) graphene (Gr) sensing film (AuNPs-Gr). The sensor consists of a single-gap gold electrode and a single layer of CVD graphene as a conducting/sensing channel decorated with a thin layer of electrochemically deposited AuNPs to catalyze the electroreduction of As(III) ions onto the sensing channel. A new detection strategy was proposed by measuring the resistance change rate of the AuNPs-Gr sensing channel modified between the source electrode and drain electrode, wherein the resistance change was caused by the electrochemical doping of As(0). The results indicated that the electrochemical doping of As(0) onto the sensing channel led to an increase in resistance through the doping interaction among As(0), AuNPs and graphene, enabling the proposed sensor to have an extraordinary detection performance with a high sensitivity. Moreover, the proposed sensor can be recycled by removing the As(0) deposited on the sensing film with the aid of a simple electrochemical oxidization process. Additionally, the mechanism of the sensing strategy based on the electrochemical n-doping of As(0) into the AuNPs-Gr sensing film was investigated using a top liquid gate electrode. The As(III) concentration detected by the AuNPs-Gr ChemFET sensor was as low as 0.001 μg/L, demonstrating that such sensors with a compatible sensing strategy can be used to detect As(III) with high sensitivity, easy fabrication, fast response and can be recycled.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

State-of-the-art and evolution of UFSD sensors design at FBK

Over the past few years, there has been growing interest in the development of silicon sensors able to simultaneously measure accurately the time of passage and the position of impinging charged particles. In this contribution, a review of the progresses in the design of UFSD (Ultra-Fast Silicon Detectors) sensors, manufactured at the FBK (Fondazione Bruno Kessler) Foundry, aiming at tracking charged particles in 4 dimensions, is presented. The state-of-the-art UFSD sensors, with excellent timing capability, are planned to be used in both ATLAS and CMS experiments detector upgrade, in order to reduce the background due to the presence of overlapping events in the same bunch crossing. The latest results on sensors characterization including time resolution, radiation resistance and uniformity of the response are here summarized, pointing out the interplay between the design of the gain layer and the UFSD performances. The research is now focusing on the maximization of the sensor fill factor, to be able to reduce the pixel size, exploring the implementation of shallow trenches for the pixel isolation and the development of resistive AC-coupled UFSD sensors. In conclusion, a brief review on research paths tailored for detection of low energy X-rays or for low material budget applications is given.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Charge collection study with the ATLAS ITk prototype silicon strip sensors ATLAS17LS

The inner tracker of the ATLAS detector is scheduled to be replaced by a completely new silicon-based inner tracker (ITk) for the Phase-II of the CERN LHC (HL-LHC). The silicon strip detector covers the volume 40 < R < 100 cm in the radial and | z | < 300 cm in the longitudinal directions. The silicon sensors for the detector will be fabricated using the n + -on-p 6-inch wafer technology, for a total of 22,000 wafers. Here, intensive studies were carried out on the final prototype sensors ATLAS17LS fabricated by Hamamatsu Photonics (HPK). The charge collection properties were examined using penetrating 90 Sr β -rays and the ALIBAVA fast readout system for the miniature sensors of 1 cm × 1 cm in area. The samples were irradiated by protons in the 27 MeV Birmingham Cyclotron, the 70 MeV CYRIC at Tohoku University, and the 24 GeV CERN-PS, and by neutrons at Ljubljana TRIGA reactor for fluence values up to 2 × 10 15 n eq /cm 2 . The change in the charge collection with fluence was found to be similar to the previous prototype ATLAS12, and acceptable for the ITk. Sensors with two active thicknesses, 300 μ m (standard) and 240 μ m (thin), were compared and the difference in the charge collection was observed to be small for bias voltages up to 500 V. Some samples were also irradiated with gamma radiation up to 2 MGy, and the full depletion voltage was found to decrease with the dose. This was caused by the Compton electrons due to the 60 Co gamma radiation. To summarize, the design of the ATLAS17LS and technology for its fabrication have been verified for implementation in the ITk. We are in the stage of sensor pre-production with the first sensors already delivered in January of 2020.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Autonomous sensor suite for evaluating fish-turbine interactions and environmental impacts in marine renewable energy and hydropower

Marine renewable energy (MRE) harnesses ocean-based resources such as waves, tides, currents, and thermal or salinity gradients for sustainable power generation. It has the potential to complement existing renewable resources, support remote communities, and contribute to decarbonization efforts. However, understanding the hydrodynamic forces created by MRE devices and their impacts on marine life is critical for responsible deployment. Here, to address these concerns, advanced sensor devices, including the Marine Sensor Fish (MSF), Sensor Fish Mini (SF Mini), and Flexible Sensor Fish (FSF), were developed to measure interactions between aquatic organisms and MRE systems. This paper details the design, manufacturing, calibration, and field deployment of these sensor suites, highlighting their ability to capture key physical stressors such as shear forces, pressure changes, and collision impacts. The MSF successfully evaluated turbine interactions at a tidal turbine in the Salish Sea, capturing data on turbulence, collision impact, and pressure gradients. The SF Mini validated hydrodynamic conditions in scaled hydraulic models, supporting computational fluid dynamics simulations. The FSF, with its flexible silicone body, measured species-specific impacts in turbulent environments. This research demonstrates the potential of Sensor Fish technology to advance sustainable marine energy systems by reducing biological impacts and informing environmentally sustainable designs.

Ecological impacts↗

DOE OSTI2021

Calibration and field deployment of low-cost sensor network to monitor underground pipeline leakage

Recent technological advances in methane detection have improved leak detection and repair. However, current methods to reliably measure methane concentrations rely on expensive instruments or demand significant labor input. There is interest in using affordable methane sensors that are responsive to ppmv level changes in methane concentrations in both urban and rural environments for monitoring underground natural gas pipeline leaks. This is especially relevant for situations where potentially significant leaks cannot be repaired immediately or smaller leaks that require long-term monitoring and further evaluation. In this work, a low-cost sensor unit, equipped with a metal oxide sensor, was designed, built, and calibrated over a wide range of methane concentrations and environmental conditions in preparation for field application. A network of these sensors was then installed at the test site and used to measure methane concentrations at ground level above known sub-surface natural gas emissions which emulated underground gas pipeline leaks. This low-cost sensor network measured over 4 days total for the two different known leakage rates. Results demonstrate that the sensors can continuously measure relative methane variability for extended periods but require calibration for a wide range of temperature and humidity conditions to properly determine absolute gas (i.e., methane) concentrations. Furthermore, when a regression analysis was conducted to evaluate the effects of meteorological parameters on methane concentration, air temperature and wind speed have strong impacts on the concentration. Overall, the network approach allows improved identification of leak location and monitoring of underground natural gas leaks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Exceptional NH 3 Detection by Cu(cyhdc) MOF Sensor Due to H 2 O Coadsorption

Metal–organic framework (MOF)-based electrical impedance sensors are a growing class of sensors that show utility in the detection of environmentally toxic gases. Detection of trace NH 3 has been particularly difficult to design due to the low electrical response of NH 3 . However, this has been circumvented by judiciously selecting a MOF that has enhanced electrical response to NH 3 due to coadsorption with predominant atmospheric gases such as water. Herein, an MOF Cu(cyhdc) based sensor has been successfully demonstrated for the enhanced detection of environmentally toxic NH 3 gas. The sensor shows a change in impedance when it is exposed to 5 ppm of NH 3 . At 20 °C, >30% relative humidity (RH) is necessary to elicit a change, with the response increasing with RH and reaching 3170× at 92% RH, producing the largest published response to NH 3 for a MOF direct electrical sensor. In the absence of water, no change is observed toward 5 ppm of NH 3 over 20–50 °C. Here, this electrical response is largely driven by huge decreases in the imaginary component of the impedance, attributed to increased capacitance at the surface of the MOF crystallites upon NH 3 and H 2 O coadsorption. Complementary structural and microstructural characterization proves that the Cu(cyhdc) crystalline structure and morphology remain intact under trace NH 3 and/or H 2 O adsorption. Despite extremely low NH 3 , loadings seen in TGA, XPS, and FT-IR confirm NH 3 and H 2 O adsorption, and changes to the metal-carboxylate IR peak positions are observed upon NH 3 adsorption. Concentrated primarily at the outer surfaces of the MOF crystallites, this NH 3 and H 2 O coadsorption effectively increases the surface capacitance across the Cu(cyhdc) powder and enables direct electrical detection of trace NH 3 . Together, these results demonstrate how coadsorption of specific molecules (H 2 O) can be used to enable the electrical detection of trace toxic gases that would otherwise not have produced a MOF sensor response.

ammonia↗

DOE OSTI2021

Cement sensors with acoustic bandgaps using carbon nanotubes

Cement is widely used in wellbores to stabilize the steel casing used in wellbore operations for oil and gas production, enhanced geothermal systems and carbon sequestration, and to limit fluid movement between sub-surface strata. Flaws such as microcracks in wellbore cement can lead to leakage along the wellbore compromising wellbore integrity. There is an increasing need for methods to monitor cement crack propagation in wellbore environments. In this study, we develop and report the first cementitious sensors capable of exhibiting high frequency acoustic bandgaps (ABGs) using carbon nanotubes (CNTs). Computational simulations of a sensor unit cell are used to design cement-multi walled carbon nanotubes (MWCNTs) sensors that show a wide bandgap. When the cement-MWCNTs sensors is embedded in cement specimens, bandgaps were measured experimentally under 300 kHz and under 600 kHz, consistent with the computationally predicted bandgaps in the range of 290–360 kHz, 410–460 kHz and 515–585 kHz. These bandgap features were absent in homogeneous cement specimens. X-ray tomographic reconstructions showed microscopic debonding at cement-MWCNTs sensor interface. Frequency response analysis of a three-dimensional computational model indicated a shift of frequency of minimum transmission due to the interface debonding, but no perturbation of bandgap response was observed. Here, the cement-MWCNTs sensors developed in this study show the potential of a packed CNT inclusion material in cementitious matrix to create ABGs in a cement matrix.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Quench detection using Hall sensors in high-temperature superconducting CORC ® -based cable-in-conduit-conductors for fusion applications

Advanced magnet systems for fusion applications would greatly benefit from the use of high-temperature superconductors (HTS). These materials allow fusion magnets to operate at higher magnetic fields, allowing for more compact fusion machines, and allow for operation at elevated temperatures, enabling demountable coils that provide access for maintenance of the fusion reactor. Quench detection remains a major challenge in the protection of HTS magnets that are vulnerable to localized conductor burnout due to their low quench propagation velocities. One of the methods explored is the use of Hall sensors that are incorporated in or near the magnet terminations that can detect local field variations that occur as a result of current redistribution within the conductor to bypass a hotspot within the magnet winding. This method is potentially well suited for Cable in Conduit Conductors, such as those made from Conductor on Round Core (CORC) cables, in which sub-cables containing HTS tapes are connected to the terminations at a low resistance. Here, to demonstrate the technique, a CORC ® triplet consisting of three sub-cables, rated for 4 kA operation at 77 K, was manufactured and Hall sensors were used to measure local field variations next to the terminations due to current redistribution between the cables. The Hall response was compared to voltages that developed over the cables and terminations as a local hotspot was applied to different cables in the triplet. It was found that the Hall sensors were faster and more sensitive than voltage contact measurements and were able to reliably detect current redistribution of only a few amperes caused by a hotspot, well before the triplet exceeded its critical current. The method also allowed the detection of heater-induced hotspots during high ramp rates of 2 kA s<:sup>–1 relevant for fusion applications. Hall sensors have a distinct benefit of being less sensitive to inductive pickup of AC interference compared to voltage contact measurements that make quench detection through voltage measurements in magnets especially challenging. The method can also be used for diagnostic measurements of current redistribution caused by other sources such as inhomogeneous current injection from faulty joints, or localized conductor damage. The Hall sensors are likely capable of detecting the onset of a quench that may occur a far distance away from the sensor location, presenting a breakthrough in HTS quench detection that potentially removes one of the remaining barriers to reliable operation of large HTS magnet systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Probing the role of CNTs in Pt nanoparticle/CNT/graphene nanohybrids H 2 sensors

Abstract In the carbon nanotubes film/graphene heterostructure decorated with catalytic Pt nanoparticles using atomic layer deposition (Pt-NPs/CNTs/Gr) H 2 sensors, the CNT film determines the effective sensing area and the signal transport to Gr channel. The former requires a large CNT aspect ratio for a higher sensing area while the latter demands high electric conductivity for efficient charge transport. Considering the CNT’s aspect ratio decreases, while its conductivity increases ( i.e. , bandgap decreases), with the CNT diameter, it is important to understand how quantitatively these effects impact the performance of the Pt-NPs/CNTs/Gr nanohybrids sensors. Motivated by this, this work presents a systematic study of the Pt-NPs/CNTs/Gr H 2 sensor performance with the CNT films made from different constituent CNTs of diameters ranging from 1 nm for single-wall CNTs, to 2 nm for double-wall CNTs, and to 10–30 nm for multi-wall CNTs (MWCNTs). By measuring the morphology and electric conductivity of SWCNT, DWCNT and MWCNT films, this work aims to reveal the quantitative correlation between the sensor performance and relevant CNT properties. Interestingly, the best performance is obtained on Pt-NPs/MWCNTs/Gr H 2 sensors, which can be attributed to the compromise of the effective sensing area and electric conductivity on MWCNT films and illustrates the importance of optimizing sensor design.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2020

Fault diagnosis and fault tolerant control for T-S fuzzy stochastic distribution systems subject to sensor and actuator faults

The problem of fault diagnosis (FD) and fault tolerant control (FTC) for a class of Takagi-Sugeno (T-S) fuzzy stochastic distribution control (SDC) systems subject to sensor and actuator faults is discussed in this paper. First, fuzzy logic models are used to approximate the output probability density function (PDF). Next, an adaptive augmented state/fault diagnosis observer is proposed to estimate the system state, sensor and the actuator faults simultaneously. New expected weights based on the sensor fault estimation information and a PI-type fuzzy feedback fault tolerant (FT) controller are designed to compensate the effect of sensor fault and actuator fault simultaneously. When the sensor fault occurs, the expected objective is redesigned to compensate the sensor fault. Meanwhile, the PI controller can compensate the effect of actuator fault, and the output PDF of the system can still track the desired PDF after the fault occurs. Finally, an example of quality distribution control in chemical reaction process is given to confirm the effectiveness of the algorithm.

42 ENGINEERING↗

DOE OSTI2025

xGFabric: Coupling Sensor Networks and HPC Facilities with Private 5G Wireless Networks for Real-Time Digital Agriculture

Advanced scientific applications require coupling distributed sensor networks with centralized high-performance computing facilities. Citrus Under Protective Screening (CUPS) exemplifies this need in digital agriculture, where citrus research facilities are instrumented with numerous sensors monitoring environmental conditions and detecting protective screening damage. CUPS demands access to computational fluid dynamics codes for modeling environmental conditions and guiding real-time interventions like water application or robotic repairs. These computing domains have contrasting properties: sensor networks provide low-performance, limited-capacity, unreliable data access, while high-performance facilities offer enormous computing power through high-latency batch processing. Private 5G networks present novel capabilities addressing this challenge by providing low latency, high throughput, and reliability necessary for near-real-time coupling of edge sensor networks with HPC simulations. This work presents xGFabric, an end-to-end system coupling sensor networks with HPC facilities through Private 5G networks. The prototype connects remote sensors via 5G network slicing to HPC systems, enabling real-time digital agriculture simulation.

Digital Agriculture↗

DOE OSTI2021

High-Temperature Multi-Process Sensor Development for a PC-Fired Unit

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 OSTI2022

Real-time sensor measurements to evaluate impacts of load cycling on high-temperature fire-side corrosion in a PC boiler

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

High-Temperature Multi-Process Sensor Development and Demonstration at Coalfired Power Plants

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 OSTI2022

Full-scale Demonstration of Multi-process Sensor at a Cycling PC-fired Boiler

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 OSTI2024

Performance Demonstration of an Occupancy Sensor-enabled Integrated Solution for Commercial Buildings

Traditionally, a single-loop fixed-gain controller is applied to supply fan (SF) and cooling coil (CC) valve controls while a fixed-damper position control is applied to outdoor air (OA) damper control at air handling units (AHUs) in commercial buildings. With the increasing application of occupancy sensors, the information generated by occupancy sensors is applied to not only reduce the electricity loads from lighting and controllable plug loads, but also reset OA intake and minimum supply airflow setpoints. Meanwhile, these intermittent operation actions greatly elevate the dynamics of AHU systems, which may introduce unstable SF and CC valve operations and inaccurate OA flow control at AHUs and consequently degrade maximum energy efficiency gains. With virtual fan and valve flow meter technologies, two advanced controls, including cascade control and gain scheduling control, can be implemented on both the SF and CC valve, and an advanced control using a virtual OA flow meter can be implemented on OA damper integrated with occupancy sensors. The goal of this project is to demonstrate the savings, cost, and performance of an integrated solution that integrates the three advanced HVAC controls with occupancy sensors to allow accurate and stable AHU operations in real buildings. The project objectives are to: 1) develop and validate an advance SF control algorithm; 2) develop and validate an advanced CC valve control algorithm; 3) validate an algorithm to implement a virtual OA flow meter; and 4) demonstrate the savings, cost, and performance of the integrated solution in real buildings. The technical approaches are to: 1) select a test system at the University of Oklahoma; 2) develop and implement the algorithms of advanced SF and CC valve controls and validate the performance; 3) develop and implement the advanced OA control using a virtual OA flow meter and validate the performance; 4) demonstrate the savings, cost, and performance of the proposed integrated solution with and without three advanced HVAC controls; and 5) disseminate the project results through publications and presentations. For the SF control, both the gain scheduling and cascade controls can improve the fan energy performance by reducing the fan power during the transient period and the fan control performance at lower speeds by reducing fan speed variation. Moreover, the gain scheduling control provides a simple and low-cost solution and is recommended. The fan power savings can reach 30% in a transient period. For the CC valve control, the gain scheduling control can considerably reduce the supply air temperature oscillation range and frequency under both higher and lower load conditions and the control valve response is much more stable. As a result, the gain scheduling control is recommended. The projected pump energy consumption can be reduced by 68.5%. With the developed virtual OA flow meter, the OA can be accurately controlled at its setpoint, which is determined based on the actual number of occupants in the building provided by occupancy sensors. The RMSE of the proposed OA control is 15.9 L/s. The energy data shows that the fan power and CC cooling energy were significantly reduced. On the other hand, the energy savings majorly results from the occupancy sensors and the energy savings by the advanced HVAC controls is minimal because that the controllers in the test AHU were tuned with very slow response. An annual technical savings potential is estimated as 0.5 quads in the commercial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Design of Zeolitic Imidazolate Framework-8-Functionalized Capacitive Micromachined Ultrasound Transducer Gravimetric Sensors for Gas and Hydrocarbon Vapor Detection

A capacitive micromachined ultrasound transducer (CMUT) was engineered and functionalized with zeolitic imidazolate framework-8 (ZIF-8) dispersed in a photoresist AZ1512HS (AZ) matrix to function as a gravimetric gas sensor. The sensor response was recorded in the presence of nitrogen, argon, carbon dioxide, and methane gases as well as water, acetylene, a propane/butane mixture, n-hexane, gasoline, and diesel vapors. The photoresist matrix alone was found to have a negligible response to all the gases and vapors, except for water vapor. No visible difference in sensor response was detected when switching from nitrogen to methane gas. However, a strong shift in the sensor resonance frequency was observed when exposed to higher hydrocarbons, ranging from 1 kHz for acetylene to 7.5 kHz for gasoline. Even longer-chain hydrocarbons, specifically kerosene and more so diesel, had a significantly reduced sensor frequency shift compared with gasoline. Sensors functionalized with a thin film of AZ+ZIF-8 demonstrated higher sensitivity in their response to a hydrocarbon molecular mass than without functionalization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Sensors with Intelligent Measurement Platform and Low-cost Equipment (SIMPLE) – Performance Characterization

Design and performance of a digital signal processing platform for enhancing off-the-shelf voltage and current sensors are presented. The platform was developed for enabling advanced distribution grid applications with existing low-cost sensors. This digital sensor system leverages a variety of off-the-shelf voltage and current sensing technologies, analog-to-digital conversion, and sensor correction algorithms to yield more accurate and reliable digital measurements that support a multitude of applications and use cases. Sample performance and accuracy results are provided, including measurements at power frequency and higher harmonics. The system extends the native performance of the medium voltage sensors used in the system, for example, broadening measurement bandwidth beyond a few kHz, appropriate for measuring switching surges and harmonics on medium voltage distribution systems. The digital sensor system is installed and characterized in the field with a high-bandwidth optical calibration system to determine site-dependent calibration and performance issues.

24 POWER TRANSMISSION AND DISTRIBUTION↗