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Robust sensing technologies allowing for 3D in-core performance monitoring in real time are of paramount importance for already established LWRs to enhance their reliability and availability per year, and therefore, to further facilitate their economic competitiveness via predictive assessment of the in-core conditions.
<ul><li style="text-align: left;">Research Background</li><li style="text-align: left;">Experimental Procedure </li><li style="text-align: left;">Results and Discussion </li><li style="text-align: left;">Conclusions </li><li style="text-align: left;">Acknowledgment and Disclaimer</li></ul>
This final technical report details research works performed supported by a Department of Energy grant (DE-FE0003859), which was awarded under the University Coal Research Program administrated by National Energy Technology Laboratory. This research program studied high temperature fiber sensor for harsh environment applications. It developed two fiber optical sensor platform technology including regenerative fiber Bragg grating sensors and distributed fiber optical sensing based on Rayleigh backscattering optical frequency domain reflectometry. Through the studies of chemical and thermal regenerative techniques for fiber Bragg grating (FBG) fabrication, high-temperature stable FBG sensors were successfully developed and fabricated in air-hole microstructured fibers, high-attenuation fibers, rare-earth doped fibers, and standard telecommunication fibers. By optimizing the laser processing and thermal annealing procedures, fiber grating sensors with stable performance up to 1100°C have been developed. Using these temperature-stable FBG gratings as sensor platform, fiber optical flow, temperature, pressure, and chemical sensors have been developed to operate at high temperatures up to 800°C. Through the integration of on-fiber functional coating, the use of application-specific air-hole microstructural fiber, and application of active fiber sensing scheme, distributed fiber sensor for temperature, pressure, flow, liquid level, and chemical sensing have been demonstrated with high spatial resolution (1-cm or better) with wide temperature ranges. These include the demonstration of 1) liquid level sensing from 77K to the room temperature, pressure/temperature sensing from the room temperature to 800C and from the 15psi to 2000 psi, and hydrogen concentration measurement from 0.2% to 10% with temperature ranges from the room temperature to 700°C. Optical sensors developed by this program has broken several technical records including flow sensors with the highest operation temperature up to 750°C, first distributed chemical measurements at the record high temperature up to 700°C, first distributed pressure measurement at the record high temperature up to 800°C, and the fiber laser sensors with the record high operation temperature up to 700°C. The research performed by this program dramatically expand the functionality, adaptability, and applicability of distributed fiber optical sensors with potential applications in a number of high-temperature energy systems such as fossil-fuel power generation, high-temperature fuel cell applications, and potential for nuclear energy systems.
An OFDR based fiber-optics sensor for distributed real-time temperature rise monitoring of a transformer in operation has been disclosed. The fiber-optic sensor provides an effective solution to monitoring the physical structures of the transformer core, as well as accurately detecting the non-uniform temperature distribution inside the transformer, and thus provides innovative feedback to the transformer design by minimizing the core losses. Additionally, the method may be responsive to the presence of magnetic and electric fields, as well as responsive to various chemical species. The method allows novel approaches to real-time asset monitoring of power transformers while operational.
Recently, there has been interest in developing a distributed temperature sensor integrated into an optical fiber. Such a system would allow embedding of the optical fiber within or on a structural material to provide for continuous monitoring of the material's temperature. Work has already begun on the development of a temperature sensor using the temperature dependent emission spectra from the lanthanide rare earths doped into crystalline hosts. The lifetime, the linewidth and the integrated intensity of this emission are each sensitive to changes in the temperature and can provide a basis for thermometry. One concept for incorporating this phenomena into an optical fiber based sensor involves bonding the optically active material to the cladding of an optical fiber and allowing the luminescent light to couple into the the fiber by the evanescent wave. Experimental work developing this concept has already been reported. Measurements of the linewidth of Eu3+:Y2O3, diffused into a fiber, made by Albin clearly show a strong and regular dependence on temperature over the range of 300 to 1000 K. We report here on a study of the temperature dependence of the lineshape of the emission at 611 nm using the data in references. We focus attention on understanding the general behavior of the Eu3+:Y2O3 system. Building upon understanding of this system we will be able to establish the physical criterial for a good optical fiber based temperature sensor and then to examine available data on other lanthanide rare earths and transition metal ions to determine the best luminescent system for temperature sensing in an optical fiber.
This work provides a summary of selected experimental capabilities being developed to support nonnuclear testing and demonstration of technology in support of microreactors under the U.S. Department of Energy’s (DOE’s) Microreactor Program. Major capabilities include the Single Primary Heat Extraction and Removal Emulator (SPHERE) and the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET). The SPHERE facility allows for controlled testing of the steady-state and transient heat rejection capabilities of a single heat pipe using electrical heaters that simulate nuclear heating. The facility is capable of monitoring axial temperature profiles along the heat pipe and surrounding test articles during startup, steady-state operation, and transients. Instrumentation includes noncontact infrared thermal imaging, surface thermocouples, spatially distributed fiber optic temperature and strain sensors, electrical power meters, and a water-cooled, gas-gap calorimeter for quantifying heat rejection from the heat pipe. The facility can be operated under both vacuum and inert-gas conditions. The MAGNET facility is a large-scale, 250-kW electrically heated microreactor test bed to enable nonnuclear experimental evaluation of a variety of microreactor concepts. It can be supplied to electrically heat a scaled section of a microreactor and further test the capabilities of heat rejection systems. The initial MAGNET experiments will support technology maturation and reduce uncertainty and risk associated with the design, operation, and deployment of monolithic heat pipe–based reactors. However, this test bed can broadly be applied to multiple microreactor concepts to evaluate a wide range of thermal-hydraulic and structural phenomena such as interface coupling with power conversion units and other collocated systems. MAGNET can evaluate integral thermomechanical effects during electrical heating of an array of heat pipes in a larger test article. Examples of initial testing will include thermal stresses in the monolith and the impact of debonding of a heat pipe from the core block and how that failure could impact surrounding heat pipes, i.e., understanding the potential for cascading failure. This work also discusses some modeling capabilities that can support experiment design, analysis, and interpretation, including the heat pipe code Sockeye and a comparison of thermal-structural simulations performed using ABAQUS and STAR-CCM+.
Optical fiber-based sensors are capable of distributed temperature and/or strain measurements with high accuracy and sub-cm spatial resolution. Optical fibers have a small diameter ({approx}100 {mu}m), a small mass (and therefore fast response time), and are fabricated from high temperature-tolerant, radiation-hard materials. These qualities make optical fiber-based instrumentation a promising candidate for in-pile sensing applications, monitoring fuel performance during irradiation in test reactors, or embedding fibers in other commercial reactor components or structures. The Department of Energy and Idaho National Laboratory are restarting the TREAT reactor (Transient Reactor Test facility) and are interested in updating the reactor's instrumentation regarding the analysis of the test fuel. The ability of optical fibers to make distributed temperature measurements coupled with its small footprint makes optical fiber a viable candidate to monitor fuel performance in the TREAT reactor. The work presented in this paper focuses on the radiation hardness of various types of optical fiber Bragg gratings. Previous experiments have shown that the inscription of Bragg gratings into optical fiber can extend the radiation survivability of distributed sensing in optical fibers, and so the goal is to determine which types of Bragg gratings survive the best in a reactor environment.
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The bottom anode in the Direct Current Electric Arc Furnace (DC EAF) is critical for completing the electrical circuit necessary for sustaining the arc within the furnace. For pin-type bottom anodes, monitoring of the temperature of select pins instrumented with thermocouples is performed to track bottom wear in the EAF and inform the operator when the furnace should be removed from service. Furthermore, this work presents the results from a plant trial using distributed temperature monitoring of bottom anode pins in a 165-ton DC EAF over a two-month service period utilizing two optical fiber sensing techniques: fiber Bragg grating (FBG) and Rayleigh backscattering (RBS). The early detection of temperature anomalies along the length of the anode pin through distributed sensing enhances operational safety, providing a robust alternative to traditional thermocouples.
The conference presents papers on distributed sensors and sensor networks, signal processing and detection techniques, temperature measurements, chemical sensors, and the measurement of pressure, strain, and displacements. Particular attention is given to optical fiber distributed sensors and sensor networks, tactile sensing in robotics using an optical network and Z-plane techniques, and a spontaneous Raman temperature sensor. Other topics include coherence in optical fiber gyroscopes, a high bandwidth two-phase flow void fraction fiber optic sensor, and a fiber-optic dark-field microbend sensor.
Liquid metal (LM) plasma-facing components (PFCs) (LM-PFCs) within next-generation fusion reactors are expected to enhance plasma confinement, facilitate tritium breeding, improve reactor thermal efficiency, and withstand large heat and particle fluxes better than solid components made from tungsten, molybdenum, or graphite. Some LM divertor concepts intended for long-pulse operation at >20 MW/m 2 incorporate thin (~1 cm), fast-moving (~5 to 10 m/s), free-surface flows. Such systems will require a range of diagnostics to monitor and control the velocity, flow depth, temperature, and impurity concentration of the LM. As such, this paper will highlight technologies developed for the fission and casting/metallurgical industries that can be adapted to meet the needs of LM-PFC research. This paper is divided into four major parts. The first part will look at noncontact flowmeter technologies that are suitable for high-temperature alkali metal systems. These technologies include rotating Lorentz-force flowmeters for bulk flow rate measurements and particle tracking techniques for surface velocity measurements. Second, this paper will detail the operation of a new inductive level sensor that can be used within free-surface LM-PFCs. This robust level sensor can be mounted below the substrate that supports the LM, so it is simple to install and is protected from the damaging conditions inside a fusion reactor. It has been shown that this level sensor can be calibrated using either numerical or experimental techniques. Third, distributed temperature sensors based on fiber-optic technologies will be discussed. This advanced measurement technique provides temperature data with high spatial resolution and has recently been successfully tested in LM systems. Last, diagnostics to measure impurity concentration, such as electrochemical cells, plugging meters, and spectroscopic systems, will be addressed.
This work provides a summary of selected experimental capabilities being developed to support non-nuclear demonstration of microreactors under the U.S. Department of Energy’s (DOE’s) Microreactor Program. Major capabilities include the single primary heat extraction and removal emulator (SPHERE) and the microreactor agile non-nuclear experimental test bed (MAGNET). The SPHERE facility allows for controlled testing of the steady-state and transient heat rejection capabilities of a single heat pipe using electrical heaters that simulate nuclear heating. The facility is capable of monitoring axial temperature profiles along the heat pipe and surrounding test articles during startup, steady-state operation, and transients. Instrumentation includes non-contact infrared thermal imaging, surface thermocouples, spatially distributed fiber-optic temperature and strain sensors, electrical power meters, and a water-cooled, gas gap calorimeter for quantifying heat rejection from the heat pipe. The facility can be operated under both vacuum and inert-gas conditions.
Distributed temperature sensing (DTS) using fiber optic sensors (FOS) offers a promising method for temperature measurements in advanced reactors, such as sodium fast reactors and molten salt cooled reactors. To support the calibration and validation of DTS measurements, Argonne National Laboratory developed the Validation, Optical Calibration, and Learning (VOCAL) software package. This report describes the integration of a local large language model (LLM) with a retrieval-augmented generation (RAG) system into the VOCAL interface to serve as an interactive user assistant. The LLM framework enhances the VOCAL platform’s accessibility to users by explaining interface components, clarifying inputs and outputs, and answering user queries dynamically in real-time. The accuracy of the LLM assistant performance was evaluated with 20 queries regarding the interface and its parameters using experimental data from the Thermal Hydraulic Experimental Test Article (THETA) facility. Results demonstrate that the LLM achieved a 95% accuracy rate, with a BERTScore of 0.8816 and SBERT value of 0.7417. Furthermore, validation of the RAG system within the LLM framework showed optimal accuracy with k-values between 1 and 2 using the k-refinement convergence test. The prompt perturbation analysis demonstrated good initial consistency for the RAG system, exhibiting the highest accuracy under punctuation variations and the greatest sensitivity under query reordering. Notably, the model’s errors were limited to data retrieval failures rather than factual hallucinations, reinforcing its baseline reliability. The integration of LLM provides a highly accurate, userfriendly enhancement to the VOCAL platform without disrupting its core computational capabilities for FOS calibration and validation.
To better understand stimulation and inter-well flow in crystalline rock with the goal of developing and improving subsurface heat exchangers for enhanced geothermal energy recovery, the EGS (Enhanced Geothermal Systems) Collab project is developing highly monitored, well- characterized intermediate scale (~10-20 m) field test beds, stimulating, and performing flow tests. These tests provide the ability to evaluate concepts, data to test and validate models, and tools to be used for EGS development, which may be evaluated at DOE’s Frontier Observatory for Research in Geothermal Energy (FORGE) project. Numerical simulation is key to the project, for experiment design and interpretation of results. Testbed characterization included optical and acoustic televiewers, full waveform seismic, electromagnetic, gamma, and temperature. The test block was further characterized using seismic tomography (p- and s-), electrical resistance tomography (ERT), and hydrologic characterization including tracer tests. Coupled process models are constrained by the detailed site characterization data. Installed monitoring systems include: 1) passive seismic/acoustic emissions; 2) continuous active source seismic; 3) ERT, with dynamic imaging using high contrast fluids; and 4) distributed acoustic, temperature, and strain fiber optic sensors. During flow and stimulation tests, fracture aperture strain monitoring is performed using the Step-rate Injection Method for Fracture In-situ Properties (SIMFIP) tool. Pressure and flow in the injection and production boreholes are monitored, and tracer tests and wavefield imaging and inversion are performed to provide additional constraints. Stimulations have been performed at several locations, connecting our injection and production wells. An overview of the EGS Collab project is presented to provide a framework for other EGS Collab presentations, along with results from numerical simulations and experiments performed at the Sanford Underground Research Facility in South Dakota.
This paper reports a technique to enhance the magnitude and high-temperature stability of Rayleigh back-scattering signals in silica fibers for distributed sensing applications. With femtosecond laser radiation, more than 40-dB enhancement of Rayleigh backscattering signal was generated in silica fibers using 300-nJ laser pulses at 250 kHz repetition rate. The laser-induced Rayleigh scattering defects were found to be stable from the room temperature to 800 °C in hydrogen gas. The Rayleigh scatter at high temperatures was correlated to the formation and modification of nanogratings in the fiber core. Using optical fibers with enhanced Rayleigh backscattering profiles as distributed temperature sensors, we demonstrated real-time monitoring of solid oxide fuel cell (SOFC) operations with 5-mm spatial resolution at 800 °C. Information gathered by these fiber sensor tools can be used to verify simulation results or operated in a process-control system to improve the operational efficiency and longevity of SOFC-based energy generation systems.
This is the final technical report for the Virginia Tech Center for Photonics Technology (VT-CPT) research project entitled “Reduced Mode Sapphire Optical Fiber and Sensing System”. The objective of the five-year effort was to develop a low modal volume (LMV) single crystal sapphire fiber and demonstrate its advantages in current state-of-the-art sapphire-based temperature sensors and in novel distributed ultra-high temperature sensing systems. The project, sponsored by the Crosscutting Research Program, began in 2014 and had the original goal of developing the next generation of harsh environment sensing systems. After successfully completing the original scope of the award, the project was expanded and extended to allow for the development of harsh environment packaging and testing of a prototype sensor system. These novel fiber optic sensing technologies provide real-time, accurate, and reliable temperature measurements at distributed locations in existing coal-fueled electricity generating units to improve the overall performance, reliability, and flexibility of the nation’s coal-fired power plant fleet. In the final year (2018) of the project, prototype sensing systems were successfully deployed and operated in small commercial coal and natural gas fired boilers at the Virginia Tech Power Plant. The harsh environment quasi-distributed temperature sensing technology was advanced from a (Technology Readiness Level) TRL=1 to a TRL=7 by demonstrating the full validation of the sensing system prototype in a relevant industrial environment. The real-time, accurate and reliable monitoring of temperatures at distributed locations is expected to lower operating costs by allowing more accurate measurement of the harsh conditions inside a boiler system to better control its operation. The technologies developed by Virginia Tech’s Center for Photonics Technology will support the mission of the National Energy Technology Laboratory (NETL) to advance energy options to fuel our economy, strengthen our security, and improve the environment.
In this conducted research, optical fiber sensors are used to measure low strength alternating magnetic fields. Various fiber sensor configurations are tested and investigated to demonstrate sensing capabilities at different field magnitudes and frequencies. Distributed acoustic sensing fibers (DAS) have been largely studied and documented across a variety of applications and sensing systems. This research uses the DAS technology in tandem with magnetostrictive materials to create a distributed multi-material optical fiber magnetic sensor. Magnetic sensing has high demand across different fields and often runs into challenges of extreme environments including high temperature, corrosion, and areas with poor accessibility. The robust and distributed nature of optical fiber sensors which can be cheaply produced for long lengths is an attractive option over other single point magnetic sensors. In down hole applications specifically, having a distributed sensor able to be deployed easily and over long distances for magnetic sensing would be a large improvement to bulkier traditional magnetometers. In the conducted study, different magnetostrictive materials are implemented in distributed optical fiber sensors to analyze and compare the effective sensitivity and potential commercial viability. Nickel, galfenol alloy, and MetGlas alloy inclusions are drawn into fused silica optical fibers with Bragg gratings inscribed later on for DAS capability. Each was investigated for its response to varying AC magnetic fields to determine relative sensitivity and resolution for distributed magnetic field sensing.
A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.