Results for “UTILITY PROGRAM DESIGN” — Page 36

DOE OSTI2022

Report for the ASCR Workshop on the Management and Storage of Scientific Data

The purpose of this workshop is to identify priority research directions in the area of data management for high-performance and scientific computing above and beyond HPC’s traditional "the parallel file system is the data-management system" model. Supporting the breadth of the DOE mission, including the explosion of AI uses and the growing needs of experimental and observational science, motivates revisiting our assumptions about data management. There are many facets of this topic to explore including: (1) Interfaces for accessing data that resides on traditional persistent storage as well as memory devices; (2) Storage-system architecture design that supports scientific workflows on varied hierarchical storage and networking devices; (3) Devising metadata management infrastructure to support FAIR principles (Findability, Accessibility, Interoperability, and Reusability); (4) Capturing provenance information about scientific data; (5) Utilizing AI to learn I/O patterns of emerging workloads for efficient data management; (6) Providing data management support for AI and complex workflows; and (7) Understanding the overlap between traditional storage systems and I/O (SSIO) efforts and data management. While the program committee has identified these topics as important areas for discussion, we welcome position papers from the community that propose additional topics of interest for discussion at the workshop. The workshop agenda will include breakout sessions for discussing these and selected topic areas to inform priority research directions for data management for high-performance and scientific computing.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

A WM Facility for the Processing of Radioactive Materials Arising from the Decommissioning Activities of the Belgian Nuclear Power Plant of Doel - 16042

Doel Nuclear Power Plant is located in the northern part of Belgium in the harbour of Antwerp on the Scheldt River. On this 80-hectare site Electrabel, the Belgian utility, operates four PWRs with a total generation capacity of 2911 MWe. Those nuclear power units were commissioned in 1975 (Doel 1 and 2 - twin units), in 1982 (Doel 3) and in 1985 (Doel 4). In light of the Belgian governments decision to definitively shutdown the oldest units of the site (Doel 1 and 2 - 433 MWe each) in 2015 at the end of their 40-year design lifetime, Electrabel launched a D and D program in partnership with Tractebel Engineering in July 2012. During the D and D preparation phase prior to the final shutdown, studies performed by Tractebel Engineering showed the added benefit of a purpose-built Waste Management Facility (WMF) specifically equipped to process contaminated and activated components generated by the in-situ dismantling activities. The WMF is a key infrastructure contributing to a large extent to the Waste Minimization Policy within the global D and D program. The present paper aims at presenting its strategic, logistic, infra-structural, and design principles. At the end of 2014, the Belgian government and Electrabel entered into discussions to envisage a 10-year lifetime extension of Doel 1 and 2 units. Therefore, Electrabel decided to put the D and D program on hold. Nevertheless, the preparatory studies for the future D and D activities on Doel site are set on solid assumptions and pave the way towards a safe, cost-effective and waste minimizing decommissioning process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Epidemiologic Studies of Radiation Workers - Paper 134

Studies of U.S. radiation workers are important because: (1) they provide information on the level of cancer and non-cancer risk following chronic exposure situations that are relevant today in medicine, occupation and environmental circumstances; (2) healthy U.S. workers are more similar to today's populations than Japanese 1945 atomic bomb survivors; (3) findings will be directly relevant to regulated worker populations; (4) organ-specific risk coefficients will be directly relevant to compensation programs; and (5) the dosimetric and epidemiologic findings can be integrated with the developing new understandings in biology for risk estimation for low doses and low dose rates. The ongoing Study of One Million U.S. Radiation Workers and Veterans is ten times larger than the study of the Japanese atomic bomb survivors of 86,000 survivors with estimated doses. The number of workers with > 100 mSv career dose is substantially greater. The large study size, broad range of doses and long follow-up indicates substantial statistical ability to quantify the risk of exposures that are received gradually over time. The study is designed to determine whether dose rate influences the future risk of cancer compared with the instantaneous exposure experienced by Japanese bomb survivors in 1945. This national effort is being coordinated by the NCRP and Vanderbilt University and includes collaborators within many government agencies (notably the DOE Low Dose Program, NRC, NASA and NCI), universities and the private sector. The study consists of 360,000 Department of Energy workers from the Manhattan Project, 150,000 nuclear utility workers from the inception of the nuclear age, 115,000 atomic veterans who participated in above ground atmospheric test at the Nevada Test Site and the Bikini Islands, 250,000 radiologists and medical workers, and 130,000 industrial radiographers. (author)

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2020

Utility Energy Service Contract Guide: A Resource for Contracting Officers Working on UESC Projects

A Utility Energy Service Contract (UESC) is a limited-source contract between a federal agency and serving utility for energy management services including energy and water efficiency improvements and demand-reduction services. In a UESC, the Contracting Officer (CO) will lead the acquisition effort, supported by technically knowledgeable staff working closely with the utility, to assess potential, investigate technical and economic feasibility, and ensure a fair and reasonable price for design and implementation of the project. The UESC Guide is a compilation of samples and templates developed as a resource to help COs implement Task Orders (TOs) for UESCs under existing U.S. General Services Administration (GSA) Areawide Contracts (AWC). All samples and templates provided in this guide were derived from actual UESC project contract documents and will be available for download on FEMP’s website at https://www.energy.gov/node/850656. Templates in Microsoft Word can be modified to address each agency’s unique acquisition process.

Federal Energy Management Program↗

DOE OSTI2018

How Successful Site Preparation Work at a Large, Commercial, Hazardous and Toxic Waste Site Can Benefit DOE Cleanup Projects - 18111

Jacobs recently completed site preparation work supporting the private commercial development of a world-scale petrochemical complex (an 'ethylene cracker' to produce the primary building block for many forms of plastic) in Monaca, Pennsylvania - the first major U.S. project of its kind outside the Gulf Coast region in 20 years and one of the largest (multi-billion dollar) construction projects in the eastern U.S. Prior to beginning construction on the petrochemical complex, the site's previous large, industrial zinc smelter operations had to be decommissioned and the facilities had to be removed. During the previous 80 years, the smelting operations at the site were used to produce zinc, lead, mercury, and sulfuric acid (a by-product of smelting). The smelting operations left landfills and industrial soil over a large area that had to be removed or closed under regulatory review to allow development across the 81,000 m{sup 2} (200-acre) industrial site located near a major river and local populations. In order to meet Pennsylvania's site-specific Land Recycling Program (commonly referred to as 'Act 2') legislative requirements, the direct contact pathway for landfill soil and slag was removed or mitigated. The site preparation work, or 'Early Works', started in January 2015. As the selected Early Works overall Engineering, Procurement, and Construction Management (EPCM) contractor, Jacobs performed the front end engineering and design. Subsequently, Jacobs had overall responsibility for procurement, construction management, health and safety, quality, security, and environmental services for the entire site and all contractors. The Early Works project included eight separate work scope packages: 1) Site Preparation, 2) Site Development, 3) Marine Works, 4) Rail Works, 5) Road Works and Offsite Utilities, 6) Site Security, 7) Construction Facilities, and 8) High Voltage Line Relocation. The Early Works scope was successfully completed in 2017. The challenges faced by this privately funded commercial project have much in common with large DOE and government construction projects. This paper explores lessons learned from the project and compares how project challenges were addressed on this private commercial project with those anticipated at large DOE/government construction and remediation sites, particularly those in the areas of Safety, Logistics, Infrastructure, and Stakeholder Involvement. The identification of best practices demonstrated on this successful project are shared for the purpose of bringing outside, commercial perspectives to ongoing or planned DOE/government construction projects. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Microgrid to enable optimal distributed energy retail and end-user demand response

In the face of unprecedented challenges in environmental sustainability and grid resilience, there is an increasingly held consensus regarding the adoption of distributed and renewable energy resources such as microgrids (MGs), and the utilization of flexible electric loads by demand response (DR) to potentially drive a necessary paradigm shift in energy production and consumption patterns. However, the potential value of distributed generation and demand flexibility has not yet been fully realized in the operation of MGs. This study investigates the pricing and operation strategy with DR for a MG retailer in an integrated energy system (IES). Based on co-optimizing retail rates and MG dispatch formulated as a mixed integer quadratic programming (MIQP) problem, our model devises a dynamic pricing scheme that reflects the cost of generation and promotes DR, in tandem with an optimal dispatch plan that exploits spark spread and facilitates the integration of renewables, resulting in improved retailer profits and system stability. Main issues like integrated energy coupling and customer bill reduction are addressed during pricing to ensure rates competitiveness and customer protection. By evaluating on real datasets, the system is demonstrated to optimally coordinate storage, renewables, and combined heat and power (CHP), reduce carbon dioxide emission while maintaining profits, and effectively alleviate the PV curtailment problem. Finally, the model can be used by retailers and MG operators to optimize their operations, as well as regulators to design new utility rates in support of the ongoing transformation of energy systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2016

GATEWAY Report Brief: OLED Lighting in the Offices of Aurora Lighting Design, Inc.

Summary of a GATEWAY report evaluation at the offices of Aurora Lighting Design, Inc., in Grayslake, IL, where the GATEWAY program conducted its first investigation involving OLED lighting. The project experienced several challenges, but also highlighted a number of promising attributes – which indicate that with continued improvements in efficacy, longevity, size, and flexibility, OLEDs could provide a new tool for creative and effective lighting.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

New Minimum Energy Performance Standard for Air Conditioners in Ecuador

This report provides technical assessment of a Minimum Energy Performance Standard (MEPS) Air Conditioner (AC) revision in Ecuador, and serves as the basis for stakeholder engagement as part of the regulatory development process to update the AC MEPS in Ecuador. This report can be used as guidance by policymakers in designing a well-founded, impactful MEPS program that is consistent with regional and international best practices and to highlight the energy, environmental, and economic benefits of the MEPS on users and the nation as a whole.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

When and Why Hiring and Training Occur: A Survey of Building Efficiency Contractors

As state and local governments, along with homeowners, work to enhance building energy performance, a sufficiently skilled energy-efficiency workforce is essential for implementing solutions at scale. In recent years, employers in the energy efficiency sector, including building performance contractors, have frequently reported challenges finding qualified workers. Additionally, as building performance technologies evolve and become more sophisticated, current workers need to acquire new skills and practices to maintain high-quality work. This study surveyed 209 contractors involved in building energy performance projects across 37 U.S. states, Washington, D.C., Guam, and the Marshall Islands. The survey aimed to understand their experiences in the labor market, their business practices, and their decision-making processes when hiring new workers and training existing employees. The findings highlight contractors' motivations and considerations in hiring and training, as well as the most significant challenges they face in the labor market. These insights can help workforce development practitioners design training programs that are aligned with workforce needs and responsive to employer concerns.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Final Technical Report for Automated Manufacturing of Innovative CPV/PV Modules

Cogenra’s Dense Cell Interconnect system was designed to use traditional front-contact cells and string them together into high efficiency and high reliability “supercells”. This novel stringer allows one to take advantage of the ~100 GW/year of existing cell production capacity and create a solar product for the customer that will produce more power and last longer than traditional PV products. The goal for this program was for Cogenra Solar to design and develop a first-of-kind automated solar manufacturing line that produces strings of overlapping cells or “supercells” based on Cogenra’s Dense Cell Interconnect (DCI) technology for their Low Concentration Photovoltaic (LCPV) systems. This will enable the commercialization of DCI technology to improve the efficiency, reliability and economics for their Low Concentration Photovoltaic systems. In this program, Cogenra Solar very successfully designed, developed, built, installed, and started up the ground-breaking manufacturing tools required to assemble supercells. Cogenra then successfully demonstrated operation of the integrated line at high yield and throughput far exceeding expectations. The development of a supercell production line represents a critical step toward a high volume and low cost Low Concentration Photovoltaic Module with Dense Cell Interconnect technology and has enabled the evaluation of the technology for reliability and yield. Unfortunately, performance and cost headwinds on Low Concentration Photovoltaics systems including lack of diffuse capture (10-15% hit) and more expensive tracker requirements resulted in a move away from LCPV technology. Fortunately, the versatility of Dense Cell Interconnect technology allows for application to flat plate module technology as well and Cogenra has worked with the DOE to utilize the learning from this grant to commercialize DCI technology for the solar market through the on-going grant: Catalyzing PV Manufacturing in the US With Cogenra Solar’s Next-Generation Dense Cell Interconnect PV Module Manufacturing Technology. This program is now very successfully building off of this work and commercializing the technology to enable increased solar adoption.

14 SOLAR ENERGY↗

DOE OSTI2025

An open control sequence specification to scale building demand flexibility via analytics software

For over two decades, researchers and practitioners have showcased the ability of large commercial buildings to provide grid services by shedding or shifting load. Various utility demand response (DR) and virtual power plant (VPP) programs throughout the United States are presently utilizing these demand-side resources. However, growth of these programs have been limited, in part due to the high cost necessary to integrate the DR control strategies into the building automation system (BAS). Implementing these strategies involves adjusting control sequences, necessitating dozens of hours of customized programming per building, limiting their adoption to large organizations and progressive owners. Recent efforts by researchers and industry have demonstrated the capability of energy management and information systems (EMIS), originally designed for fault detection and diagnostics, to interface with existing BAS and perform supervisory control to optimize building operations. While these approaches are quickly being adopted by industry, demand flexibility (DF) control strategies remain limited in product offerings. One of the challenges is the lack of documented best-practice DF sequences, despite the rich literature on field implementations. This paper develops a new open-specification for a zone-based temperature adjustment shed strategy for commercial building HVAC systems, describing the specification’s implementation in two EMIS tools in both experimental and field settings. Both implementations successfully reduced electric load by at least 40% on average during the called event, while maintaining temperature limits. This study’s detailed process from specification to deployment shows the potential for scalability as well as highlights challenges related to integration with heterogeneous BAS products.

Granderson, Jessica↗

DOE OSTI2024

Control over Conformational Landscapes of Polypeptoids by Monomer Sequence Patterning

The ability to program chain conformation and structure through control over the monomer sequence of synthetic polymers has broad implications for next-generation material design. While related problems of protein-folding and de novo design have generated accurate predictions of 3D folded chain structures, generalization to synthetic polymers remains intractable due to the requirement of large structural databases and the intrinsically disordered nature of polymer building blocks. In this work, polypeptoids, a class of peptidomimetic synthetic polymers, are utilized to build a general workflow for the study of relationships between monomer sequence and dynamic 3D chain structure in solution. Furthermore, this work demonstrates how control over the monomer sequence can alter the conformational landscape of synthetic polymers to deviate dramatically from classical chain statistics. Specifically, the distribution of end-to-end distances, as measured by double electron-electron resonance spectroscopy in dilute solvent, is systematically skewed towards shorter distances with an increasing number of hydrophobes and further refined by hydrophobe arrangement in amphiphilic polypeptoid chains.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Taking the Challenge at Singer Village--A Cold Climate Zero Energy Ready Home

After progressively incorporating ENERGY STAR(R) for Homes Versions 1, 2, and 3 into its standard practices over the years, this builder, Brookside Development, was seeking to build an even more sustainable product that would further increase energy efficiency, while also addressing indoor air quality, water conservation, renewable-ready, and resiliency. These objectives align with the framework of the DOE Challenge Home program, which 'builds upon the comprehensive building science requirements of ENERGY STAR for Homes Version 3, along with proven Building America innovations and best practices. Other special attribute programs are incorporated to help builders reach unparalleled levels of performance with homes designed to last hundreds of years.' CARB partnered with Brookside Development on the design optimization and construction of the first home in a small development of seven planned new homes being built on the old Singer Estate in Derby, CT.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Kentucky Codes Compliance Improvement Study

The project was funded through the U.S. Department of Energy (DOE) Funding Opportunity Announcement (FOA), “Strategies to Increase Residential Energy Code Compliance Rates and Measure Results” (DE-FOA-0000953). A primary goal was to determine whether an investment in education, training, and outreach programs could produce a significant, measurable change in single-family residential energy use, and therefore energy savings, within 2-3 years. DOE ultimately intended for public and private entities to use this information to justify and catalyze additional future investments in energy code training, education and related energy-efficiency improvement programs. The project was structured in three phases: Measure the pre-program compliance rate using a DOE-developed methodology that provides statewide results with 90/10 statistical reliability; Implement education, training, and outreach activities designed to increase code compliance, and; Measure the post-program compliance rate using the same methodology as the pre-program study. Pacific Northwest National Laboratory (PNNL) developed the procedures and methodology implemented as part of the project, constructed the public data set, and conducted all resulting analysis.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

ESnet Requirements Review Program Through the IRI Lens: A Meta-Analysis of Workflow Patterns Across DOE Office of Science Programs (Final Report)

The Department of Energy (DOE) ensures America’s security and prosperity by addressing its energy, environmental, and nuclear challenges through transformative science and technology solutions. The DOE’s Office of Science (SC) delivers groundbreaking scientific discoveries and major scientific tools that transform our understanding of nature and advance the energy, economic, and national security of the United States. The SC’s programs advance DOE mission science across a wide range of disciplines and have developed the research infrastructure needed to remain at the forefront of scientific discovery. The DOE SC’s world-class research infrastructure — exemplified by the 28 SC scientific user facilities — provides the research community with premier observational, experimental, computational, and network capabilities. Each user facility is designed to provide unique capabilities to advance core DOE mission science for its sponsor SC program and to stimulate a rich discovery and innovation ecosystem. Research communities gather and flourish around each user facility, bringing together diverse perspectives. A hallmark of many facilities is the large population of students, postdoctoral researchers, and early-career scientists who contribute as full-fledged users. These facility staff and users collaborate over years to devise new approaches to utilizing the user facility’s core capabilities. The history of the SC user facilities has many examples of wildly inventive researchers challenging operational orthodoxy to pioneer new vistas of discovery; for example, the use of the synchrotron X-ray light sources for study of proteins and other large biological molecules. This continual reinvention of the practice of science — as users and staff forge novel approaches expressed in research workflows — unlocks new discoveries and propels scientific progress. Within this research ecosystem, the high-performance computing (HPC) and networking user facilities stewarded by SC’s Advanced Scientific Computing Research (ASCR) program play a dynamic cross-cutting role, enabling complex workflows demanding high performance data, networking, and computing solutions. The DOE SC’s three HPC user facilities and the Energy Sciences Network (ESnet) high-performance research network serve all of the SC’s programs as well as the global research community. Argonne Leadership Computing Facility (ALCF), the National Energy Research Scientific Computing Center (NERSC), and Oak Ridge Leadership Computing Facility (OLCF) conceive, build, and provide access to a range of supercomputing, advanced computing, and large-scale data-infrastructure platforms, while ESnet interconnects DOE SC research infrastructure and enables seamless exchange of scientific data. All four facilities operate testbeds to expand the frontiers of computing and networking research. Together, the ASCR facilities enterprise seeks to understand and meet the needs and requirements across SC and DOE domain science programs and priority efforts, highlighted by the formal requirements reviews (RRs) methodology. In recent years, the research communities around the SC user facilities have begun experimenting with and demanding solutions integrated with HPC and data infrastructure. This rise of integrated-science approaches is documented in many community and high-level government reports. At the dawn of the era of exascale science and the acceleration of artificial intelligence (AI) innovation, there is a broad need for integrated computational, data, and networking solutions. In response to these drivers, DOE has developed a vision for an Integrated Research Infrastructure (IRI): To empower researchers to meld DOE’s world-class research tools, infrastructure, and user facilities seamlessly and securely in novel ways to radically accelerate discovery and innovation.

42 ENGINEERING↗

DOE OSTI2020

Development of Miniaturized High Temperature Multi Process Monitoring System

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

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2021

A. Development of Miniaturized High Temperature Multi Process Monitoring System

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

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2021

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↗