Results for “multi objective” — Page 26

DOE OSTI2020

Multi-Gas Sensors for Enhanced Reliability of SOFC Operation

GE Research, in partnership with SUNY Polytechnic Institute (SUNY Poly), designed, built, and tested gas sensors for in situ monitoring of H 2 and CO anode tail gases produced with on-site steam reforming in solid oxide fuel cell (SOFC) systems. The knowledge of the H 2 /CO ratio of these anode tail gases should allow accurate determination and control of the efficiency of the reforming process in the SOFC system and should deliver a lower operating cost for SOFC customers. The project objectives were to achieve multi-gas monitoring capability with a single multivariable sensor, and to sustain this performance in the presence of gaseous interferences and a potential poison for the sensor. The duration of the project was 24 months with the project structure that included three technical tasks such as (1) development of design rules of photonic nanostructures for H 2 and CO gas detection, (2) laboratory validation of photonic nanostructures for selective H 2 and CO gas detection, and (3) validation of photonic nanostructures for initial stability and poison-resistance against H 2 S. To build multivariable sensors for selective H 2 and CO gas detection in the presence of interferences, we expanded our earlier knowledge of multi-gas sensors into new fabrication and functionalization methodologies as well as into new methodologies for the spectral data analysis of multi-gas responses. We have advanced our design rules of the three-dimensional (3D) photonic nanostructures that allowed detection of H 2 and CO at high temperatures as individual gases and as their mixtures and rejection of interferences such as CO 2 , H 2 O, CH 4 , and other hydrocarbons for SOFC applications. Our advanced design rules should be attractive for building the new generation of cost-effective industrial sensors. Stability and poison resistance of our 3D photonic nanostructures was tested in the laboratory conditions. While initially we utilized conventional machine learning data analysis tools, we have found that they were unable to correct for the sensor drift. Thus, we have implemented new methods of machine learning for the analysis of our spectral data. These learnings pave the way to move the future studies into advanced testing of effects of interferences, aging and field tests. In future, our work will continue to advance our sensing designs to operate in conditions with known and unknown interferences by implementing nanostructures with enhanced spectral diversity of responses to gaseous species of interest and interferences. Our systematic reduction of technical risks in this completed project and in future studies will ensure transition of this sensing technology to commercialization.

03 NATURAL GAS↗

DOE OSTI2022

Environmentally Adaptive, Multiband Software-Defined-Radar for Monitoring of Item of Interest in a Dynamically Cluttered Room

High-resolution multi-frequency radars when networked together, form a robust and seamless monitoring system for high-valued items. The multi-look-direction radar network investigated by LLNL and DSI, operates at 77 GHz and 5.8GHz, and is capable of detection at centimeter resolution movement of objects of interest. This dual frequency radar (unlike optical methods) can operate under various environments with conditions such a smoke, dust, and other natural or manmade obscurations. In addition, the multiband network radar is based on low-cost FCC approved EM specifications and can be scaled with the dimensions of the room and objects under consideration by user-defined inputs. Furthermore, the underlying radar signal processing based on software-defined radar engine is adaptive to its operational environment, where operators can input the size of the facility and object of interest and the distance between the object and radar. Finally, this multi-frequency radar employs a host of change detection and machine learning algorithms to reach performance levels in terms of high probability of detection and low false alarm rates while the monitoring state of the object can be reported remotely.

42 ENGINEERING↗

DOE OSTI2020

SMART Mobility. Multi-Modal Freight Capstone Report

The U.S. Department of Energy’s Systems and Modeling for Accelerated Research in Transportation (SMART) Mobility Consortium is a multiyear, multi-laboratory collaborative, managed by the Energy Efficient Mobility Systems Program of the Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office, dedicated to further understanding the energy implications and opportunities of advanced mobility technologies and services. The first three-year research phase of SMART Mobility occurred from 2017 through 2019, and included five research pillars: Connected and Automated Vehicles, Mobility Decision Science, Multi-Modal Freight, Urban Science, and Advanced Fueling Infrastructure. A sixth research thrust integrated aspects of all five pillars to develop a SMART Mobility Modeling Workflow to evaluate new transportation technologies and services at scale. This report summarizes the work of the Multi-Modal Freight Pillar. The Multi Modal Freight Pillar’s objective is to assess the effectiveness of emerging freight movement technologies and understand the impacts of the growing trends in consumer spending and e-commerce on parcel movement considering mobility, energy, and productivity. For information about the other Pillars and about the SMART Mobility Modeling Workflow, please refer to the relevant pillar’s Capstone Report.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Asteroids seen by JWST-MIRI: Radiometric size, distance, and orbit constraints

Infrared measurements of asteroids are crucial for the determination of physical and thermal properties of individual objects, and for understanding the small-body populations in the solar system as a whole. However, standard radiometric methods can only be applied if the orbit of an object is known, hence its position at the time of the observation. With JWST-MIRI observations the situation will change and many unknown, often very small, solar system objects will be detected. Later orbit determinations are difficult due to the faintness of the objects and the lack of dedicated follow-up concepts. We present MIRI observations of the outer-belt asteroid (10920) 1998 BC1 and an unknown object, detected in all nine MIRI bands in close apparent proximity to (10920). We developed a new method called STM-ORBIT to interpret the multi-band measurements without knowing the object’s true location. The power of the new technique is that it determines the most-likely heliocentric and observer-centric distance and phase angle ranges, allowing us to make a radiometric size estimate. The application to the MIRI fluxes of (10920) was used to validate the method. It leads to a confirmation of the known radiometric size-albedo solution, and puts constraints on the asteroid’s location and orbit in agreement with its true orbit. To back up the validation of the method, we obtained additional ground-based light curve observations of (10920), combined with Gaia data, which indicate a very elongated object (a/b ≥ 1.5), with a spin-pole at (λ, β) ecl = (178°, +81°), with an estimated error of about 20°, and a rotation period of 4.861191 ± 0.000015 h. A thermophysical study of all available JWST-MIRI and WISE measurements leads to a size of 14.5–16.5 km (diameter of an equal-volume sphere), a geometric albedo pV between 0.05 and 0.10, and a thermal inertia in the range 9–35 (best value 15) J m -2 s -0.5 K -1 . For the newly discovered MIRI object, the STM-ORBIT method revealed a size of 100–230 m. The new asteroid must be on a low-inclination orbit (0.7° < i < 2.0°) and it was located in the inner main-belt region during JWST observations. A beaming parameter η larger than 1.0 would push the size even below 100 meters, a main-belt regime that has escaped IR detections so far. This kind of MIRI observations can therefore contribute to formation and evolution studies via classical size-frequency studies, which are currently limited to objects larger than about one kilometer in size. We estimate that MIRI frames with pointings close to the ecliptic and short integration times of only a few seconds will always include a few asteroids; most of them will be unknown objects.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Dosimetric delivery validation of dynamically collimated pencil beam scanning proton therapy

Pencil beam scanning (PBS) proton therapy target dose conformity can be improved with energy layer-specific collimation. One such collimator is the dynamic collimation system (DCS), which consists of four nickel trimmer blades that intercept the scanning beam as it approaches the lateral extent of the target. While the dosimetric benefits of the DCS have been demonstrated through computational treatment planning studies, there has yet to be experimental verification of these benefits for composite multi-energy layer fields. The objective of this work is to dosimetrically characterize and experimentally validate the delivery of dynamically collimated proton therapy with the DCS equipped to a clinical PBS system. Approach. Optimized single field, uniform dose treatment plans for 3 × 3 × 3 cm 3 target volumes were generated using Monte Carlo dose calculations with depths ranging from 5 to 15 cm, trimmer-to-surface distances ranging from 5 to 18.15 cm, with and without a 4 cm thick polyethylene range shifter. Treatment plans were then delivered to a water phantom using a prototype DCS and an IBA dedicated nozzle system and measured with a Zebra multilayer ionization chamber, a MatriXX PT ionization chamber array, and Gafchromic™ EBT3 film. Main results. For measurements made within the SOBPs, average 2D gamma pass rates exceeded 98.5% for the MatriXX PT and 96.5% for film at the 2%/2 mm criterion across all measured uncollimated and collimated plans, respectively. For verification of the penumbra width reduction with collimation, film agreed with Monte Carlo with differences within 0.3 mm on average compared to 0.9 mm for the MatriXX PT. Significance. We have experimentally verified the delivery of DCS-collimated fields using a clinical PBS system and commonly available dosimeters and have also identified potential weaknesses for dosimeters subject to steep dose gradients.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2020

Local Phasor-Based Control of DER Inverters for Voltage Regulation on Distribution Feeders

We introduce a new control paradigm termed Phasor-Based Control (PBC) to coordinate Distributed Energy Resources (DER) for improved voltage regulation and other objectives. PBC is a multi-layer control framework where the state of the distribution grid is represented by voltage phasors, and Phasor Measurement Units (PMUs) measure the state at critical points in the distribution grid. In the PBC paradigm, a supervisory controller (S-PBC) sets phasor targets which local controllers track. In this paper, we propose a Proportional Integral (PI) implementation for the local control layer (LPBC), to regulate real and reactive power output of distributed inverters to track a voltage phasor target computed by the supervisory layer. We tune the PI controller gains offline with a genetic algorithm that yields better performance than the Ziegler-Nichols method. We benchmark the proposed L-PBC controller against droop volt-var control (DVVC) and observe improved voltage regulation in simulation on the IEEE 13 node unbalanced test feeder (IEEE 13NF). Furthermore, by means of numerical simulation we observe the response of the L-PBC controllers to small and large grid disturbances. Simulations on larger feeders, IEEE 123-node and 647-node, demonstrate challenges with tuning controllers in setups with different amounts of power-voltage coupling.

42 ENGINEERING↗

DOE OSTI2023

Design and Optimization of a Fast-Switching Electromagnetic Valve Actuator for Off-highway Vehicle Hydraulic Systems

Electrification of off-highway vehicles offers improved efficiency and reduction in greenhouse gas emissions. However, the extremely low power densities of electric machines relative to the hydraulics used in conventional off-highway vehicles makes electrification challenging. Although the recently proposed Hybrid Hydraulic Electric Architecture (HHEA) can overcome this limitation, it requires frequent switching between the pressure rails using switching valves resulting in losses. Fast switching minimizes the switching losses in these valves, which otherwise significantly reduce the overall efficiency of the system. The primary contribution of this paper is the design and optimization of a linear electromagnetic actuator for a fast-switching valve. This paper identifies the actuator requirements to enable fast switching and presents a design and optimization technique to realize actuators that meet the design objectives. In addition, a multi-physics approach is proposed to model the performance of the complete switching valve by considering the electromagnetic, fluidic, and mechanical physics. An optimal actuator design is obtained using the developed optimization framework, and the multi-physics model demonstrates that the selected design achieves a 30% reduction in throttling-related switching losses by switching 70 % faster than comparable commercial valve designs.

Linear actuators, off-highway vehicle electrificat↗

DOE OSTI2022

MARSAME Radiological Release Report for Diamond Drive Widening and Roundabout Construction Projects

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has determined that only a portion of the soil associated with the Diamond Drive Widening/Roundabout Projects (Figure 1) meets the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020). The remaining soil did not meet the criteria for unrestricted release and must be managed appropriately. These conclusions are based on the known history of the area combined with soil sample data collected in 2022; the findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

MARSAME Radiological Release Report for Replacement Water Lines from TA-48 to TA-55

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has determined that only a portion of the soil associated with Replacement Water Lines from Technical Area (TA)-48 to TA55 (Figure 1) meets the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020). The remaining soil did not meet the criteria for unrestricted release and must be managed appropriately. These conclusions are based on the known history of the area combined with soil sample data collected in 2022; the findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

MARSAME Radiological Release Report for Diamond Drive Widening and Roundabout Construction Projects, Revision 1

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has determined that the soil, concrete and asphalt associated with the Diamond Drive Widening/Roundabout Projects (Figure 1) meets the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020). These conclusions are based on the known history of the area combined with soil sample data collected in 2022; the findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

MARSAME Radiological Release Report for Weapons Facility Operations #5 Decontamination and Demolition Project

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has identified materials associated with Weapons Facility Operations (WFO) #5 that meet the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020) and materials in one building that did not meet the criteria for unrestricted release and are to be treated as low level waste (LLW). These conclusions are based on the known history of the area combined with radiation survey data data collected in 2022 and 2023. The findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

MARSAME Radiological Release Report for Weapons Facility Operations #4 Decontamination and Demolition Project: TA-14-0005, TA-15-0009, TA-15-0202, TA-15-0233, TA-36-0019

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has identified materials associated with Weapons Facility Operations (WFO) #4 that meet the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020) and materials in one building that do not meet the criteria for unrestricted release and are to be treated as low level waste (LLW). These conclusions are based on the known history of the buildings combined with radiation survey data data collected in 2022 and 2023. The findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program. The scope of this final release report includes Technical Area (TA) 14 Building 5 (TA-14-0005), TA-15 Buildings 9, 202, and 233 (TA-15-0009/0202/0233), and TA-36 Building 19 (TA-36-0019). MARSAME provides guidance on statistical sampling for residual radionuclides in bulk materials; smaller, miscellaneous items can be released via the release procedures outlined in LANL Policy 121 Radiation Protection (LANL, 2023).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

MARSAME Release Report for Replacement Water Lines From TA-48 to TA-55, Revision 2

Environmental Protection and Compliance, Environmental Stewardship (EPC-ES) has determined that only a portion of the soil associated with Replacement Water Lines from Technical Area (TA)-48 to TA 55 (Figure 1) meets the criteria for unrestricted release to the public under Department of Energy (DOE) Order 458.1, Radiation Protection for the Public and the Environment (DOE, 2020). The remaining soil did not meet the criteria for unrestricted release and must be managed appropriately. These conclusions are based on the known history of the area combined with soil sample data collected in 2022; the findings are consistent with DOE Order 458.1 and Los Alamos National Laboratory (LANL) Functional Series Document EPC-ES-FSD-004, Environmental Radiation Protection (LANL, 2021). Sampling and data analysis, as described in this report, were sufficient to meet measurement quality objectives (MQOs) under the Multi-Agency Radiation Survey and Assessment of Materials and Equipment (MARSAME) manual (NUREG, 2009) and LANL procedures (LANL, 2020). Final approvals for waste disposition will come from LANL’s Waste Management Program.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

RAPIDS2: A SciDAC Institute for Computer Science, Data, and Artificial Intelligence (University of Delaware)

This report summarizes the activities, technical accomplishments, and outcomes of the RAPIDS2 Institute project at the University of Delaware (UD). The RAPIDS2 Institute was a large multi-institution project with the objective of assisting SciDAC and Office of Science application teams in the use of DOE supercomputing resources to achieve scientific breakthroughs. The UD team contributed to this effort through work on formal software verification. This thrust aims to reduce software developer time and effort, especially regarding debugging and testing, and to increase confidence in the correctness of the results computed by the software.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Detecting and Characterizing Fracture Zones Using a Convolutional Neural Network

This project directly supports the Geothermal Technologies Office (GTO) objectives outlined in the Multi-Year Program Plan (MYPP) by advancing two key research areas: “Exploration and Characterization” and “Data, Modeling, and Analysis.” This project has successfully demonstrated a pre-drilling ability to image and characterize the distribution and connectivity of subsurface faults and fractures, key parameters for identifying permeable pathways that enable geothermal fluids to circulate and produce energy. Specifically, we developed and implemented innovative machine learning methodologies to enhance geothermal exploration. Large-scale faults were detected using a Convolutional Neural Network (CNN), while small-scale fractures were characterized using a novel Double-Beam Neural Network (DBNN). These tools have proven both technically effective and cost-efficient by reducing reliance on expensive exploratory drilling. Through collaboration with our geothermal industry partner, this research has significantly advanced techniques for identifying hidden geothermal systems and extending the productive lifespan of existing geothermal fields. We applied our methods to two geothermal fields—Soda Lake (Nevada) and Lightning Dock (New Mexico)—to identify shallow steam-charged fracture zones and characterize deep faults at depths of 1.5-2 km. The steam zone identified at the Soda Lake geothermal field showed excellent agreement with prior drilling data, validating the effectiveness of our approaches. In addition, the analysis revealed three new prospective drilling targets for further development and verification. The outcomes of this project improve our scientific understanding of geothermal reservoir behavior, enhance exploration efficiency, extend the economic life of existing geothermal plants. Ultimately, these advancements contribute to GTO’s goal of achieving more sustainable, affordable, and data-driven geothermal energy development across the United States.

15 GEOTHERMAL ENERGY↗

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 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↗