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At least 55 records · Page 3

Distributed Wind Market Report: 2022 Edition

The 2022 edition of the Distributed Wind Market Report provides stakeholders with statistics and analysis of the distributed wind market— which includes power from wind turbines installed near where the power will be used—along with insight into market trends and characteristics. The report analyzes distributed wind projects of all sizes and details the U.S. small wind market for the 2021 calendar year.

17 WIND ENERGY↗

Offshore Wind in the US Gulf of Mexico: Regional Economic Modeling and Site-Specific Analyses

The goal of this study is to assess offshore wind energy resources in the Gulf of Mexico (GOM) and to quantify its technical and economic potential in order to inform Federal and GOM state strategic energy planning over the next decade. The objectives are to: describe site-specific and regional benefits and challenges of deploying offshore wind in the GOM and discuss the current research to mitigate challenges; review and quantify the wind resource capacity and energy potential in the GOM region for each GOM state including state and federal waters, distance from shore, and water depth; perform geospatial regional economic assessments of levelized cost of energy (LCOE), levelized avoided cost of energy (LACE), and net value (Section 3.4.2); evaluate three representative hypothetical locations for site-specific analysis; perform a high-level assessment of local supporting infrastructure availability, including existing services (e.g., fabrication facilities, vessels, ports) and possible grid connection options; assess the regional economic impacts of a 600 megawatt (MW) offshore wind power plant installed at a representative site in the GOM.

17 WIND ENERGY↗

Technical Geothermal Roadmap for Indonesia

The technical geothermal roadmapping exercise described by this report is part of the NZW Collaborative Work Program with the Government of Indonesia. Indonesia currently has the second largest installed geothermal power generation capacity in the world and has abundant undeveloped resources that allow for continued expansion of its geothermal resource development, which can serve to contribute to the country’s goal of achieving net zero emissions for power generation by 2060. The DOE GeoVision study (2019) highlighted the importance of technical improvements as the key for accelerating the development of geothermal resources in the United States by reducing the costs and risks to make geothermal more competitive, and this also applies to Indonesia. The main objective of the roadmap is to identify and discuss key technical challenges and discuss how implementation of geothermal technology advances could reduce the risks, costs, and time associated with geothermal exploration and development activities and expand the potential resource base to include unconventional resource types, thus accelerating geothermal deployment in Indonesia.

15 GEOTHERMAL ENERGY↗

Aluminum Electrolytic Capacitor Vulnerability Evaluation in DC Power Supplies at the Spallation Neutron Source

The service life of electrolytic capacitors is a concern for long-term reliable operation of power supplies. The Power Conversion Group at the Spallation Neutron Source (SNS) facility of Oak Ridge National Laboratory is responsible for more than 500 power supplies with over 1000 electrolytic capacitors installed in these power supplies. Most of the electrolytic capacitors have been in operation since 2007 and are either well over or close to the manufacturer provided lifetime. This paper addresses this vulnerability to ensure continued reliable operation of the SNS. The power supply circuit is simulated in a MATLAB/Simulink environment to quantify the capacitor ripple current and operating voltage. Combined with manufacturer data, this information is used to estimate capacitor lifetime. Utilizing the simulation results and lifetime projections of the capacitors, capacitor replacements for the power supplies is prioritized. To assess end-of-life, the ambient temperature and ripple current of the capacitor is used. Based on the manufacturer's data and scientific literature review, capacitor end-of-life is established. The results of the simulations and analysis is presented. Data on the highest priority supplies will also be presented, and statistics on the capacitor performance, reliability and remaining lifetime will be shown.

Harave, Sudarshan↗

Making Northway, Alaska Resilient and Sustainable Through Energy Efficiency and Solar Power

This project implemented energy efficiency measures and installed 6 kW solar arrays on three community buildings in Northway, Alaska, in a collaboration between the Department of Energy - Office of Indian Energy Policy and Programs, the Northway Village Council (NVC), the Tanana Chiefs Conference (TCC), and the Alaska Native Tribal Health Consortium (ANTHC). Northway is a small community in interior Alaska, close to the Canadian border, with high fuel and energy costs: $3.00 per gallon of diesel and $0.56 per kWh, respectively, in 2016, when the project began. The energy efficiency and solar power installation plans aligned with Northway’s long-term energy goals of increasing renewable energy and decreasing reliance on fossil fuels, per the Northway Community Energy Action Plan, the Alaska Interior Regional Energy Plan, and TCC Comprehensive Economic Development Strategy. The project focused on three buildings: (1) the community hall (and later office) building, (2) the washeteria building, and (3) the water/sewer garage. It included multiple directions for energy efficiency measures, such as installing LED lighting upgrades, programmable thermostats, vending machine energy misers, efficient pumps, and adding glycol loops at the water/sewer plant. Since the village has a high potential for solar energy, in order to increase resilience and decrease costs, solar systems were installed on three community buildings. Later, a battery was installed in the community hall to capture solar power produced but not used during the day, and allow the flexibility to use that power during evening and night, further decreasing the reliance on grid power for that building. Electricity savings realized by the village between 2011-2012 and 2018-2019 by improving energy efficiencies in the buildings and adding solar was 23%. This is despite the community hall doubling in size during the same time period. If that is taken into consideration (by adding community hall usage into the 2011-2012 usage one additional time), the energy savings from 2011-2012 to 2018-2019 was 37%.

14 SOLAR ENERGY↗

Northern Region Coal Prospects

This presentation was delivered to the audience attending the U.S. DOE/USEA Northern Regional Coal Workshop in Bismarck, ND on March 11, 2026. The presentation highlights the opportunity for coal plants in the region to provide power to military installations and data centers. There is also an analysis on how coal-fired power stations maintain regional supply during extreme cold weather events. Finally, a summary slide is presented that highlights a recent business case analysis on diverting captured carbon dioxide for use in enhanced oil recovery in the Bakken.

Bakken↗

Cost targets to achieve commercially viable thermal storage in buildings

To mitigate the variation in demand on the electric grid, thermal energy storage (TES) is an alternative to electric batteries or installing new peaking power plants. Stakeholders and policy makers across the United States have expressed interests in promoting TES, as demonstrated by the US Department of Energy’s Grid-Interactive Efficient Buildings program and the efforts of various state legislatures. However, the cost value provided by TES are unclear. If reliable cost benefits were determined, stakeholders would have a clearer picture of the financial returns that can be gained from their investment in TES. In this report, EnergyPlus was used to perform whole-building simulations for two residential buildings in Indianapolis and Atlanta. The HVAC system in both buildings were equipped with phase change material TES. The TES tank was charged in off-peak hours and discharged in peak hours to perform load shifting. First, the economic value implied by existing time-of-use (TOU) rates offered by utility companies was analyzed via whole-building simulation. Second, existing demand reduction (DR) incentives sourced from 3 different electrical grid administrators (i.e., California, Texas, and New England region) were surveyed to determine their implied value. Lastly, the economic value implied by different types of deferred peak power plants were reviewed. The full value of TES to the entire society consists of value to the utility, OEMs, facility installers, and other stakeholders. This report focuses on the value to the utility with emphasis on the deferred capital of peak power plant. The value from the deferred capital of peak power plant is manifested to the customer in the form of demand reduction program and Time-of-Use utility rate program. In this report, an initial proxy of the value of TES is made by assuming the deferred capital cost of power plant is the full value to reduce peak demand. Three levels of financial value of TES systems were assessed. Two are currently available to some residential customers: (1) the benefit from TOU pricing alone and (2) the benefit from TOU pricing in combination with DR incentive programs. The third level was computed as the full cost of deferred capital cost of peaking power plants. This represents the potential value that could be gained by the utilities or conceivably be offered to consumers.

25 ENERGY STORAGE↗

A Tutorial on the Control of Floating Offshore Wind Turbines: Stability Challenges and Opportunities for Power Capture

Climate change is a serious threat facing humanity. The United States (U.S.) and many other countries are increasing the amount of electrical power generated from renewable energy sources in an effort to combat climate change and ensure energy independence. The U.S. has set goals to achieve a 100% decarbonized electric grid by 2035 and a net-zero emissions economy by no later than 2050. Renewable energy currently accounts for about 20% of the U.S. power grid. According to the U.S. Department of Energy and the National Renewable Energy Laboratory (NREL), in the U.S. in 2021, wind and solar photovoltaic generation supplied 9.1% and 4% of total electricity generation, respectively, and the latest publicly available data show that hydropower represented 6.6% of all electricity generated in the U.S. in 2019. As wind farms have been built in many of the best wind resource areas on land, the U.S. and many other countries are turning to offshore wind for further growth of wind power capacity. Further, the U.S. has committed to deploy 30 GW of offshore wind by 2030, a significant increase from the 0.04 GW of installed offshore wind in the country as of the end of 2023. Many other countries have also established ambitious goals or plans to increase the amount of installed offshore wind power.

17 WIND ENERGY↗

Characterizing electrical demand and load diversity of low-power water and space heating appliances in US homes

Home renovation and remodeling projects can involve costly and time consuming electrical infrastructure upgrades at the household level. From the grid perspective they also lead to costly replacement of local infrastructure, such as transformers, and can add stress to the grid at peak times. The emergence of innovative, power-efficient household appliances offers a way to minimize these problems. These appliances are designed for lower power consumption, simplifying installation through standard plug-in connections, reducing the need for new electric circuits/panels/service, and minimizing the peak power demand for the home. Key examples include low-power heat pump water heaters (HPWHs) and cold climate window heat pumps that operate on standard 120V outlets. To assess the real-world impact of these solutions, we compiled and analyzed power metering data from several US field studies. This data provides insights into the effects on peak power demand of selecting lower-power appliances. Our analysis focuses on several key metrics, including the maximum power demand of individual appliances, their operational runtime, continuous operation and load diversity. While individual low-power 120V space and water heating appliances offer significant peak demand reductions compared to 240V heat pump or resistance alternatives, their longer runtimes might increase the likelihood of operation during whole-dwelling peak events, albeit at lower power levels.

Less, Brennan↗

2023 Risk Management Plan and Register for Low-Power WEC for Non-Grid Applications

This is an updated risk management plan and risk register for the design, build and test of a novel, remote, low-power wave energy converter (WEC) for non-grid applications. This Columbia Power Technologies project seeks to develop a prototype low-power WEC that lowers the total cost of ownership and provides robust, new capabilities for customers in the maritime environment. The testing location for this prototype is the U.S. Navy Wave Energy Test Site (WETS) in Kaneohe Bay, O'ahu, Hawai'i. Detailed in the Risk Management Plan document is a Failure Modes, Effects, and Criticality Analysis (FMEC) that systematically identifies all potential failure modes and their effects on the system. Risk registers for major subsystems were completed according to the methodology described in the Risk Management Plan and are also included here.

16 TIDAL AND WAVE POWER↗

Historical Pattern Analysis of Global Geothermal Power Capacity Development: Preprint

Between 1913 and 1958, Italy was the only country with an operational geothermal power plant until New Zealand installed its first plant in 1958. At present, 24 countries are involved in the geothermal power market, and they have a combined installed capacity of 16,127 GW. This study analyzes the historical patterns of geothermal power capacity in the world and in individual countries to investigate the ideal global geothermal development pattern by examining the annual cumulative capacity (ACC) and the annual capacity addition (ACA) graphs of the historical development of geothermal power capacity in 24 countries. First, the global patterns are analyzed using these graphs in five periods (1945-1957, 1958-1976, 1977-1991, 1992-2002, and 2003-2020) that are marked by a series of characteristics of ACA peaks separated by two major troughs. Then, five characteristic patterns are developed in five periods globally. These patterns correspond to the early-stage linear, the first acceleration, the first steady-state linear, the second acceleration, and the second steady-state linear developments. A positive relationship exists between global patterns and the 5-year shifted oil-price curve: two major factors influenced global development: 1) increasing oil prices and increasing awareness of global climate change, and 2) global development of geothermal power. Last, we investigate these patterns in each country. The top ten countries, which comprise 93.3% of the world's total installed capacity are separated into five groups based on the availability and characteristics of patterns globally developed in five periods. Group-1 (the United States) has an installed capacity of 3,794 MW, Group-2 (Mexico and Philippines) 963-1935 MW, Group-3 (New Zealand, Italy, Iceland, and Japan) 601-1,037 MW, and Group-4 (Indonesia, Kenya, and Turkiye) 944-2,356 MW. The remaining 14 countries (6.7%), which are called Group 5, are still in an immature stage and have installed capacities of 7-262 MW and are not involved in pattern analysis. Overall, geothermal power in the world is in its third stage of development, which had its peak development after 1977. A fourth development peak may be expected to occur after this through business-as-usual cases. The biggest barrier to the development of the global geothermal power market is the risk associated with exploration and drilling. If risk mitigation systems and funds are employed, the growth of geothermal power production projects could accelerate.

GEOTHERMAL ENERGY↗

Historical Pattern Analysis of Global Geothermal Power Capacity Development

Between 1913 and 1958, Italy was the only country with an operational geothermal power plant until New Zealand installed its first plant in 1958. At present, 24 countries are involved in the geothermal power market, and they have a combined installed capacity of 16,127 GW. This study analyzes the historical patterns of geothermal power capacity in the world and in individual countries to investigate the ideal global geothermal development pattern by examining the annual cumulative capacity (ACC) and the annual capacity addition (ACA) graphs of the historical development of geothermal power capacity in 24 countries. First, the global patterns are analyzed using these graphs in five periods (1945-1957, 1958-1976, 1977-1991, 1992-2002, and 2003-2020) that are marked by a series of characteristics of ACA peaks separated by two major troughs. Then, five characteristic patterns are developed in five periods globally. These patterns correspond to the early-stage linear, the first acceleration, the first steady-state linear, the second acceleration, and the second steady-state linear developments. A positive relationship exists between global patterns and the 5-year shifted oil-price curve: two major factors influenced global development: 1) increasing oil prices and increasing awareness of global climate change, and 2) global development of geothermal power. Last, we investigate these patterns in each country. The top ten countries, which comprise 93.3% of the world's total installed capacity are separated into five groups based on the availability and characteristics of patterns globally developed in five periods. Group-1 (the United States) has an installed capacity of 3,794 MW, Group-2 (Mexico and Philippines) 963-1935 MW, Group-3 (New Zealand, Italy, Iceland, and Japan) 601-1,037 MW, and Group-4 (Indonesia, Kenya, and Turkiye) 944-2,356 MW. The remaining 14 countries (6.7%), which are called Group 5, are still in an immature stage and have installed capacities of 7-262 MW and are not involved in pattern analysis. Overall, geothermal power in the world is in its third stage of development, which had its peak development after 1977. A fourth development peak may be expected to occur after this through business-as-usual cases. The biggest barrier to the development of the global geothermal power market is the risk associated with exploration and drilling. If risk mitigation systems and funds are employed, the growth of geothermal power production projects could accelerate.

GEOTHERMAL ENERGY↗

Hydrogen Mitigation Process Testing at Nevada Solar One

The National Renewable Energy Laboratory (NREL) and Acciona Solar Power (ASP) developed and installed a process that addresses the issue of hydrogen buildup in Acciona's Nevada Solar One power plant. Our method selectively removes hydrogen from the expansion tanks of the power plant to control hydrogen levels in the circulating heat-transfer fluid (HTF). During previous work, we developed a sensor that measures hydrogen partial pressure in the expansion-tank headspace gas. We demonstrated that our sensor measures hydrogen levels over a wide range of partial pressure from 10 mbar down to 0.003 mbar. More recently, we conceived and developed an integrated process module that performs both hydrogen sensing and separating functions. The sensor/separator measures hydrogen partial pressure in the headspace gas in the same way as our original sensor design. Additionally, the integrated module separates hydrogen from the headspace gas to reduce hydrogen to the level needed to maintain the performance of receivers in the collector field. Laboratory testing at NREL showed that the sensor function had an accuracy of +/-7%, and the hydrogen extraction rate for separator function was consistent with our modeling predictions. The primary benefit of this module is its simple design, both in terms of function and incorporation into the HTF subsystem of the power plant. Most recently, NREL and ASP completed installation and initial testing of a mitigation process at ASP's Nevada Solar One power plant in Boulder City, Nevada. In this paper, we report on the completed installation, initial testing, and plans to bring the process to full automation, so that it can be operated unattended on a daily schedule.

chemical elements↗

Development of Miniaturized High Temperature Multi Process Monitoring System

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

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

A. Development of Miniaturized High Temperature Multi Process Monitoring System

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

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

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↗

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↗

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↗