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DOE OSTI2021

Sensor impacts on building and HVAC controls: A critical review for building energy performance

Building operations rely heavily on control systems and sensors. This paper provides a sophisticated literature review on sensor systems in building/HVAC systems, particularly in the context of controls, and their impacts on energy efficiency and thermal comfort. This study aims to understand the previous and current research and identify future research opportunities on this subject. The reviewed sensor systems were used for heuristic rule-based controls, local controls, and advanced optimal controls for existing and emerging technologies. Five major aspects of sensors are reviewed here: control loops for sensors, sensor types, sensor locations, sensor data, and a sensor impact evaluation framework. To augment the literature review, comprehensive standardized interviews were also conducted with relevant industry experts and practitioners. These interviews were designed and performed to (1) identify significant factors for selecting sensor sets and current undergoing issues, (2) identify potential improvements in sensor configuration/deployment, and (3) integrate expert (e.g., researcher, building operation practitioner) knowledge and experiences to develop structured use-case scenarios. Researchers collected and analyzed 31 interview responses for this paper.

Building control↗

DOE OSTI2022

Development and testing of a performance evaluation methodology to assess the reliability of occupancy sensor systems in residential buildings

With the emergence of advanced occupancy sensor technologies to better detect occupancy in buildings, a universal methodology and metrics are required to evaluate and report sensor systems’ reliability and compare the performance across multiple sensor systems. Herein this research presents a methodology to assess the reliability of occupancy sensor systems in residential buildings in a controlled laboratory environment, including both “typical” and “failure” testing scenarios. The developed methodology was then implemented to evaluate a novel occupancy detection sensor system’s reliability. “Typical” testing evaluates the overall accuracy of the sensor system, which suggest how reliable the occupancy sensor system is over time. Results show that on average, the precision and recall are 0.75 and 0.70, indicating similar numbers of false positives and false negatives across the dataset. The overall accuracy of the tested sensor system was 62.4% to 76.4%. Failure testing results indicate whether there are influential variables impacting the sensor performance. For the tested sensor system, the number of occupants, presence of large objects, presence of interior light sources, and number of doors are not influential, while lighting level, location of occupants, additional door in the entry/exit area, and having the TV on are variables determined to impact the sensor system performance.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

A portable and reusable sensor system based on graphene for real-time and sensitive detection of lead ions in water

Long-term exposure to Pb 2+ can cause irreversible damage to the nervous, cardiovascular, and reproductive systems. Therefore, developing a fast and sensitive detection system capable of monitoring minuscule concentrations of Pb 2+ is essential. In this study, we demonstrated a fully portable sensor system enabling rapid, sensitive, and real-time monitoring of Pb 2+ . The sensor system adopted the remote-gate field-effect transistor (RGFET) detection scheme and was easy to operate, even for non-experts. The sensor system comprised two printed circuit boards (PCBs): a sensor PCB with a remote-gate electrode and an analyzer PCB with a metal-oxide-semiconductor field-effect transistor (MOSFET) transducer and peripheral electronics to manage sensor signals. To achieve a high sensitivity for Pb 2+ , we utilized graphene ink drop-casted on the sensor PCB as a sensing membrane. The graphene film was easy to deposit and remove, enabling the sensor PCB to be reused multiple times. The sensor system was further linked to a smartphone application that instantly monitors the sensor response, allowing for rapid point-of-use detection. The sensor exhibited a high sensitivity of 21.7% when the limit of detection (LOD) value of 1 nM (∼0.2 ppb) was detected, and the typical detection time for each sample was approximately 60 seconds. This portable sensor system advances sensing technologies and could potentially supplement expensive, laborious conventional sensing equipment.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Passively-Powered Adaptively-Located Flexible Hybrid Sensors Final Report

PARC, a Xerox Company, is developing a low-cost system of peel-and-stick wireless sensors that will enable widespread building environment sensor deployment with the potential to deliver up to 30% energy savings. The system is embodied by a set of RF hubs that provide power to the automatically located sensor nodes, and relays data wirelessly to the building management system (BMS). The sensor nodes are flexible electronic labels powered by rectified RF energy transmitted by a RF hub and can contain multiple printed and conventional sensors. The system design overcomes limitations in wireless sensors related to power delivery, lifetime, and cost by eliminating batteries and photovoltaic devices. The sensor label can be equipped with a variety of printed and conventional sensors for building energy optimization, including lighting, occupancy, temperature, humidity, motion, and air quality. A key advantage of this system is its ability to automatically locate multiple sensor nodes to within 0.5 m (at a 5-m read distance) for simplified commissioning, as well as its interoperability with a wide range of existing BMS hardware and software. This enables automatic sensor reconfiguration and recommissioning, which is an important cost reduction driver. Moreover, the sensors are compatible with low-cost-, high-throughput roll-to-roll manufacturing, further reducing system costs. Upon successfully developing, manufacturing and deploying the system with optimized control, it can lead to annual primary energy savings >280 TBtu in offices, and up to ~1850 TBtu in combined offices and residences. The technology is based on PARC innovations in small antenna design, efficient RF energy capture, and flexible electronics. PARC is a leader in flexible hybrid integration similar to what is used in current RFID tags, which will provide a low-cost system in a flexible form factor. Our team member, Energy ETC, is a leader in supplier-agnostic BMS deployments, and will design the commissioning and deployment procedures to maximize system interoperability. The project will result in a demonstrator that will provide temperature and humidity data and will be wirelessly integrated into PARC’s BMS.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Distributed Wireless Antenna Sensors for Boiler Condition Monitoring

Monitoring the operational conditions of coal-fired boilers is an important task that could bring tremendous benefits, including in-situ process control, real-time health assessment of structural components, improved heat transfer efficiency, reduced downtime, etc. Moreover, in-situ distributed sensing of the boiler conditions would provide large scale in-situ measurement data that will help us gain fundamental understandings of the combustion and heat transfer processes as well as enable the developments of new simulation tools, which could eventually lead to better design and more efficient operation of the boilers. The objectives of this research were to (a) develop wireless passive antenna sensors without electronics; (b) demonstrate multi-modality sensing using a signal antenna sensor; and (c) fabricate the antenna sensor from high-temperature materials. In this project, we have demonstrated that an antenna sensor or sensor array without any electronics can be wirelessly interrogated from a distance. In addition, a low-cost compact wireless sensor interrogator was developed for dynamic interrogation of the passive antenna sensor. We validated that a dual-frequency antenna sensor is capable of simultaneous strain and temperature measurements or temperature and ash accumulation measurements; all parameters are relevant to boiler condition monitoring. By measuring the temperature and ash accumulation height simultaneously, the dielectric constant of the ash as well as its temperature dependency can also be characterized. This capability could lead to potential applications of the antenna sensor for combustion process monitoring based on the ash composition. We also investigated different techniques of fabricating the antenna sensor using high-temperature materials such as alumina substrate and platinum paste and characterized the thermal response of the antenna sensor. A linear relationship between the antenna resonant frequency and the temperature change was validated.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

A Review of Existing Test Methods for Occupancy Sensors

One of the key new features of connected lighting systems (CLS) is their ability to collect data from various types of integral sensors and share that data with other lighting or building systems. Occupancy and vacancy sensors have been widely adopted as an energy-saving strategy in buildings, yet published test methods for reproducibly characterizing their performance remain few and limited in their sophistication. As a result, it has been difficult to predict their performance in a specific application, and in practice, they frequently do not meet energy-savings expectations. Occupants at times remove or otherwise bypass occupancy sensors that hinder their work or otherwise do not perform as expected, thereby compromising the sensors’ potential to reduce energy consumption. Poor performance can result from multiple causes – ranging from fundamental limitations of the sensor technology, to misconfiguration, to poor placement in the room or space. Innovative occupancy sensors, some of them combining multiple sensing technologies, have come on the market over the years, with claims of improved performance compared to their predecessors; yet in practice, their performance has led to neither high deployment nor high user satisfaction in any significant application, nor has it differed enough from the performance of previous products to necessitate a test method that facilitated comparison between them. While the performance of both common and novel occupancy sensors has been the subject of many published research articles, the test methods that have been employed for them have typically been loosely described and incorporated custom equipment or techniques that render them difficult to reproduce, or have been limited in their ability to fairly characterize devices that utilize varying sensor technology. The lack of a well-described, technology-agnostic test method that yields reproducible results across different implementations has been a barrier to the commercial success of new occupancy sensor products, as users and specifiers who have been disappointed with previous products are often unwilling to take a chance with new ones. Motivated by a desire to fairly characterize new technologies that continue to enter the market and claim not only improved occupancy detection but, in some cases, also additional capabilities (e.g., the ability to measure traffic or discern between different object types), this report presents the results of a literature review of recent published, well-described test methods for characterizing occupancy sensor performance, as well as research articles containing ad-hoc test methods. The review also identifies and consolidates the best techniques for characterizing sensor performance in indoor spaces and identifies test method gaps that need to be filled in order to evaluate emerging technologies and products.

47 OTHER INSTRUMENTATION↗

DOE OSTI2016

A downhole CO 2 sensor to monitor CO 2 movement in situ for geologic carbon storage

Here this paper describes how a downhole CO 2 chemical sensor was prepared for use in determining the concentration of CO 2 in water, particularly in harsh, high-pressure environments such as those found in geological formations considered for the geologic storage of CO 2 . The sensor consisted of a pair of Ir/IrO x and Ag/AgCl electrodes, a gas-permeable membrane, a bicarbonate-based internal electrolyte solution, and porous stainless steel as supporting material. The sensor was tested in the solution with different concentrations of CO 2 and displayed very good CO 2 sensing performance under pressures of 1000, 2000, and 3000 psi. A linear relationship between the sensor response potential and the logarithm of the CO 2 concentration was obtained for the sensor under different pressures. Reproducibility of the sensor was examined and the results indicated that the sensor displayed excellent reproducibility. CO 2 /brine core flooding tests were carried out to evaluate the performance of the CO 2 sensor in simulate CO 2 storage process. The results indicated that the sensor could detect CO 2 movement in the tests. Further studies showed that the sensor could be reused by brine flooding after CO 2 /brine flushed the core. The results of the core flooding tests demonstrated that the sensor had potential application for CO 2 monitoring in carbon storage.

25 ENERGY STORAGE↗

DOE OSTI2025

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗

DOE OSTI2012

Leak Detection and H 2 Sensor Development

Low-cost, durable, and reliable Hydrogen safety sensor for vehicle, stationary, and infrastructure applications. A new zirconia, electrochemical-based sensor technology is being transitioned out of the laboratory and into an advanced testing phase for vehicular and stationary H 2 safety applications. Mixed potential sensors are a class of electrochemical devices that develop an open-circuit electromotive force due to the difference in the kinetics of the redox reactions of various gaseous species at each electrode/electrolyte/gas interface, referred to as the triple phase boundary (TPB). Therefore, these sensors have been considered for the sensing of various reducible or oxidizable gas species in the presence of oxygen. Based on this principle, a unique sensor design was developed by LANL and LLNL. The uniqueness of this sensor derives from minimizing heterogeneous catalysis (detrimental to sensor response) by avoiding gas diffusion through a catalytically active material and minimizing diffusion path to the TPB. Unlike the conventional design of these devices that use a dense solid electrolyte and porous thin film electrodes (similar to the current state-of-the-art zirconia-based sensors and fuel cells), the design of this sensor uses dense electrodes and porous electrolytes. Such a sensor design facilitates a stable and reproducible device response, since dense electrode morphologies are easy to reproduce and are significantly more stable than the conventional porous morphologies. Moreover, these sensors develop higher mixed potentials since the gas diffusion is through the less catalytically active electrolyte than the electrode. Lastly, the choice of electrodes is primarily based on their O2 reduction kinetics and catalytic properties vis-a-vis the target gas of interest.

08 HYDROGEN↗

DOE OSTI2023

Assessment of Flow-Enhanced Electrochemical Sensor Testing and Deployments for MSRs

This report serves as the deliverable for Milestone M3RS-23AN0401061 that is part of Work Package RS-23AN040106 (Flow Enhanced Sensors for MSRs – ANL). The goal of this milestone was to determine performance of the flow enhanced electrochemical sensor (FEES) and modular flow instrumentation testbed (MFIT) in safeguards relevant scenarios. Flow enhanced electrochemical sensors are a type of electroanalytical sensor that has been developed at Argonne National Laboratory to be installed directly into MSR flow conduits to make measurements of the salt composition. These sensors represent a significant improvement in capabilities compared to earlier electroanalytical sensors that instead can only be operated in quiescent conditions. Previous work has focused on testing of the FEES in flowing conditions provided by the MFIT to assess the accuracy and precision of the sensor measurements. To further improve this capability, in FY23 we undertook a campaign of safeguards relevant scenarios in molten salt containing a range of uranium chloride concentrations (0 to 3 wt%). All the testing carried out in FY23 was aided by a control system designed to automatically actuate flow conditions and collect data. This new automation system is estimated to have increased experimental throughput by a factor of four and enabled testing in a variety of complex conditions. The advancements in throughput and repeatability led to improved quantification of actinide concentrations using the in-flow sensors, with a reduction of the mean absolute relative error from 5.6% in FY22 to 3.1% in FY23. In addition to safeguards scenarios run in the MFIT, FY23 work included deployment of a FEES at a partner institution where it will be tested in a flowing salt loop. The FEES was successfully integrated into that loop and is being tested prior to loop startup. In FY23, work also continued on the smaller flow system that we have named the mini-MFIT. This smaller system is capable of rapid prototyping of new sensor designs prior to installation in the larger MFIT radiological flow system. Work was carried out to test this new system in non-radiological molten salts in a separate glovebox. This work is helping us to enhance the accuracy of our salt monitoring capabilities through the integration of multiple types of sensors. The high degree of accuracy required by 10 CFR 74 represents a significant challenge, and further design evolution and integration of the sensors into multimodal sensing frameworks will be needed to further push the measurement accuracy to the needed level.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Addressing Low-Cost Methane Sensor Calibration Shortcomings with Machine Learning

Quantifying methane emissions is essential for meeting near-term climate goals and is typically carried out using methane concentrations measured downwind of the source. One major source of methane that is important to observe and promptly remediate is fugitive emissions from oil and gas production sites but installing methane sensors at the thousands of sites within a production basin is expensive. In recent years, relatively inexpensive metal oxide sensors have been used to measure methane concentrations at production sites. Current methods used to calibrate metal oxide sensors have been shown to have significant shortcomings, resulting in limited confidence in methane concentrations generated by these sensors. To address this, we investigate using machine learning (ML) to generate a model that converts metal oxide sensor output to methane mixing ratios. To generate test data, two metal oxide sensors, TGS2600 and TGS2611, were collocated with a trace methane analyzer downwind of controlled methane releases. Over the duration of the measurements, the trace gas analyzer’s average methane mixing ratio was 2.40 ppm with a maximum of 147.6 ppm. The average calculated methane mixing ratios for the TGS2600 and TGS2611 using the ML algorithm were 2.42 ppm and 2.40 ppm, with maximum values of 117.5 ppm and 106.3 ppm, respectively. A comparison of histograms generated using the analyzer and metal oxide sensors mixing ratios shows overlap coefficients of 0.95 and 0.94 for the TGS2600 and TGS2611, respectively. Overall, our results showed there was a good agreement between the ML-derived metal oxide sensors’ mixing ratios and those generated using the more accurate trace gas analyzer. This suggests that the response of lower-cost sensors calibrated using ML could be used to generate mixing ratios with precision and accuracy comparable to higher priced trace methane analyzers. This would improve confidence in low-cost sensors’ response, reduce the cost of sensor deployment, and allow for timely and accurate tracking of methane emissions.

03 NATURAL GAS↗

DOE OSTI2020

Virtual Pressure Sensor for Electronic Expansion Valve Control in a Vapor Compression Refrigeration System

Virtual sensor technology, which uses simulation models/algorithms to calculate a value to represent an unmeasured variable or replace a directly measured reading, has attracted many studies in the heating, ventilation, air conditioning and refrigeration (HVAC&R) industry. However, most virtual sensor technologies are developed for fault detection and diagnostics (FDD) purposes, which generally compare the virtual sensor values with actual measured values to detect if any fault occurred and identify the causes that led to the fault. It is rare to see studies focus on control performance of virtual sensors after substituting an actual sensor. This is particularly important for the system with no redundant sensor since a virtual sensor is the most effective way to operate the system in the desirable region when any sensor failure occurs. To address this gap, this paper develops a new virtual pressure sensor technology to substitute the actual pressure measurement for electronic expansion valve (EXV) control in a vapor compression refrigeration system by integrating compressor and valve characteristics. The control performance of this proposed virtual pressure sensor technology under various operating conditions is validated with experimental data. Closed loop EXV control simulations with the proposed virtual pressure sensor are conducted, and the results are analyzed.

47 OTHER INSTRUMENTATION↗

DOE OSTI2016

Robust Ceramic Coaxial Cable Down-Hole Sensors for Long-Term In Situ Monitoring of Geologic CO 2 Injection and Storage

Energy generation by use of fossil fuels produces large volumes of CO 2 and other greenhouse gases, whose accumulation in the atmosphere is widely seen as undesirable. CO 2 Capture followed by sequestration has been identified as the solution. Subsurface geologic formations offer a potential location for long-term storage of CO 2 because of their requisite size. Unfortunately, the inaccessibility and complexity of the subsurface, the wide range of scales of variability, and the coupled nonlinear processes, impose tremendous challenges to determine the transport and predict the fate of the stored CO 2 . Among the various monitoring approaches, in situ down-hole monitoring of the various state parameters provides critical and direct data points that can be used to validate the models, optimize the injection, detect leakage and track the CO 2 plume. However, down-hole sensors that can withstand the harsh conditions and operate over decades of the project lifecycle remain unavailable. Given that the widespread of carbon capture and storage will be the necessity and reality in the future, fundamental and applied research is required to address the significant challenges and technological gaps in lack of long-term reliable down-hole sensors This project focused on the development and demonstration of a novel, low-cost, distributed, robust ceramic coaxial cable sensor platform for in situ down-hole monitoring of geologic CO 2 injection and storage with high spatial and temporal resolutions. The coaxial cable Fabry-Perot interferometer (CCFPI) has been studied as a general sensor platform for in situ, long-term, measurement of temperature, pressure and strain, which are critical to CO 2 injection and storage. A novel signal processing scheme has been developed and demonstrated for dense multiplexing of the sensors for low-cost distributed sensing with high spatial resolution. The developed temperature, pressure and strain sensors have been extensively tested under laboratory conditions that are similar to the downhole CO 2 storage environment, showing excellent capability for in situ monitoring the various parameters that are important to model, optimize the injection, detect leakage and track the CO 2 plume. In addition, the interactions between the sensor datum and the geological models have been investigated in details for the purposes of model validation, guiding sensor installation/placement, enhancement of model prediction capability and optimization of the injection processes. This project has resulted in the successful development of new ceramic coaxial cable based sensor systems that can monitor directly the changes in pressure, temperature, and strain caused by increased reservoir pressure and reduced reservoir temperature due to the supercritical CO 2 injection. Integrated with geological models, the sensors and measurement data can improve the possibility to identify plume movement and leakage in the cap rock and wells with higher precision and more accuracy. The low cost, ease of deployment, small size and dense multiplexing features of the new sensing technology will allow a large number of sensors to be deployed to address the objective to demonstrate that 99% of the CO 2 remains in the injection zone.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2015

Fully depleted CMOS pixel sensor development and potential applications

CMOS pixel sensors are often opposed to hybrid pixel sensors due to their very different sensitive layer. In standard CMOS imaging processes, a thin (about 20 μm) low resistivity epitaxial layer acts as the sensitive volume and charge collection is mostly driven by thermal agitation. In contrast, the so-called hybrid pixel technology exploits a thick (typically 300 μm) silicon sensor with high resistivity allowing for the depletion of this volume, hence charges drift toward collecting electrodes. But this difference is fading away with the recent availability of some CMOS imaging processes based on a relatively thick (about 50 μm) high resistivity epitaxial layer which allows for full depletion. This evolution extents the range of applications for CMOS pixel sensors where their known assets, high sensitivity and granularity combined with embedded signal treatment, could potentially foster breakthrough in detection performances for specific scientific instruments. One such domain is the Xray detection for soft energies, typically below 10 keV, where the thin sensitive layer was previously severely impeding CMOS sensor usage. Another application becoming realistic for CMOS sensors, is the detection in environment with a high fluence of non-ionizing radiation, such as hadron colliders. However, when considering highly demanding applications, it is still to be proven that micro-circuits required to uniformly deplete the sensor at the pixel level, do not mitigate the sensitivity and efficiency required. Prototype sensors in two different technologies with resistivity higher than 1 kΩ, sensitive layer between 40 and 50 μm and featuring pixel pitch in the range 25 to 50 μm, have been designed and fabricated. Various biasing architectures were adopted to reach full depletion with only a few volts. Laboratory investigations with three types of sources (X-rays, β-rays and infrared light) demonstrated the validity of the approach with respect to depletion, keeping a low noise figure. Especially, an energy resolution of about 400 eV for 5 keV X-rays was obtained for single pixels. The prototypes have then been exposed to gradually increased fluences of neutrons, from 10{sup 13} to 5x10{sup 14} neq/cm{sup 2}. Again laboratory tests allowed to evaluate the signal over noise persistence on the different pixels implemented. Currently our development mostly targets the detection of soft X-rays, with the ambition to develop a pixel sensor matching counting rates as affordable with hybrid pixel sensors, but with an extended sensitivity to low energy and finer pixel about 25 x 25 μm{sup 2}. The original readout architecture proposed relies on a two tiers chip. The first tier consists of a sensor with a modest dynamic in order to insure low noise performances required by sensitivity. The interconnected second tier chip enhances the read-out speed by introducing massive parallelization. Performances reachable with this strategy combining counting and integration will be detailed. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Flexible Fabric-Based IDC Sensors for Conformal Curved Surface Applications

Interdigital capacitor (IDC) sensors are attractive in-situ sensors that can be used to measure permittivity variations in materials. Such sensors could be powerful enablers for cable insulation aging detection. Since insulation aging is correlated with a change in its material permittivity an IDC can measure that change via its measured capacitance. A new thin, flexible fabric-based IDC sensor is introduced for application on conformal curved surfaces such as an electrical cable surface. A multielectrode IDC and its backplane were fabricated using conductive copper polyester taffeta fabrics that were adhesively bonded to nonconductive polyester fabric. The sensor because of its soft flexible structure eliminates the problem of sensor conductor damage which is common for printed circuit board (PCB) type sensors when conformed to the surface of a cable. It also significantly reduces the airgap between the electrodes and the surface that they must contact in order to measure the capacitance. Airgap reduction and consistency are important in order to accurately predict permittivity variations in cable insulation material due to aging. Both PCB-based sensors and the new fabric-based sensors were built and tested on unaged cables and cables that underwent accelerated aging. Results demonstrate the proposed advantages of the novel fabric-based IDC sensor.

interdigital capacitor sensor, IDC, NDE, PCB senso↗

DOE OSTI2017

Wireless microwave acoustic sensor system for condition monitoring in power plant environments

This project successfully demonstrated novel wireless microwave acoustic temperature and pressure sensors that can be embedded into equipment and structures located in fossil fuel power plant environments to monitor the condition of components such as steam headers, re-heat lines, water walls, burner tubes, and power turbines. The wireless microwave acoustic sensor technology researched and developed through a collaborative partnership between the University of Maine and Environetix Technologies Corporation can provide a revolutionary impact in the power industry since it is anticipated that the wireless sensors will deliver reliable real-time sensing information in harsh power plant conditions that involve temperatures up to 1100oC and pressures up to 750 psi. The work involved the research and development of novel high temperature harsh environment thin film electrodes, piezoelectric smart microwave acoustic sensing elements, sensor encapsulation materials that were engineered to function over long times up to 1100oC, and a radio-frequency (RF) wireless interrogation electronics unit that are located both inside and outside the high temperature harsh environment. The UMaine / Environetix team have interacted with diverse power plant facilities, and identified as a testbed a local power generation facility, which burns municipal solid waste (MSW), the Penobscot Energy Recovery Company (PERC), Orrington, Maine. In this facility Environetix / UMaine successfully implemented and tested multiple wireless temperature sensor systems within the harsh-environment of the economizer chamber and at the boiler tubes, transferring the developed technology to the power plant environment to perform real-time sensor monitoring experiments under typical operating conditions, as initially targeted in the project. The wireless microwave acoustic sensor technology developed under this project for power plant applications offers several significant advantages including wireless, battery-free, maintenance-free operation, and operation in the harsh-environment of power plant equipment up to about 1100 oC. Their small size and configuration allows flexible sensor placement and embedding of multiple sensor arrays into a variety of components within power systems that can be interrogated by a single RF unit. The outcomes of this project and technological transfer respond to a DOE analysis need, which indicated that if one percent efficiency in coal burning is achieved, an additional 2 gigawatt-hours of energy per year is generated and the resulting coal cost savings is $300 million per year, also accompanied by a reduction of more than 10 million metric tons of CO2 per year emitted into the atmosphere. Therefore, the developed harsh environment wireless microwave acoustic sensor technology and the technological transfer achievements that resulted from the execution of this project have significant impact for power plant equipment and systems and are well-positioned to contribute to the cost reduction in power generation, the increase in power plant efficiency, the improvement in maintenance, the reduction in down-time, and the decrease in environmental pollution. The technology is also in a position to be extended to address other types of high-temperature harsh-environment power plant and energy sector sensing needs.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2018

First bulk and surface results for the ATLAS ITk Strip stereo annulus sensors

A novel microstrip sensor geometry, the stereo annulus, has been developed for use in the end-cap of the ATLAS experiment’s strip tracker upgrade at the HL-LHC. Its first implementation is in the ATLAS12EC sensors, a large-area, radiation-hard, single-sided, AC-coupled, n + -in-p design produced by the ITk Strip Sensor Collaboration and fabricated by Hamamatsu Photonics in early 2017. The results of the initial testing of two ATLAS12EC batches are presented here with a comparison to specification. The potential of the new sensor shape to reinvigorate endcap strip tracking is explained and its effects on sensor performance are isolated by comparing the bulk mechanical and electrical properties of the new sensor to the previous iteration of prototype, the conventional barrel ATLAS12A sensor. The surface properties of the new sensor are evaluated for full-size unirradiated sensors as well as for mini sensors unirradiated and irradiated with protons up to a fluence of 2.2 x 10 15 n eq cm -2 . The results show that the new stereo annulus ATLAS12EC sensors exhibit excellent performance and the expected irradiation evolution.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Long-Term Infrasound Sensor Calibration and Characterization

Previous testing has shown that infrasound sensors deployed in the field can exhibit notable deviations from their nominal, lab-based calibrations. These variations may be due to changes in environmental conditions, long-term sensor drift, or other unresolved features. In early 2018, we installed two identical infrasound elements with five infrasound sensors at each element (Chaparral M50A, Chaparral M64LN, CEA/Martec MB2005, CEA/Seismowave MB3a, and Hyperion IFS-5113A). These sensors were accepted or under consideration for use in the International Monitoring System network of the Comprehensive Nuclear-Test-Ban Treaty. Each element had all sensors connected to a single digitizer and port to the atmosphere. We also recorded instrument enclosure air temperature and humidity and external air temperature. Using the MB2005 as the reference, we examine the relative sensor response (both magnitude and phase) as a function of time and frequency and compare it with quarterly laboratory calibrations and environmental conditions. Here, we find that the magnitude response for all sensors exhibits some variability in both the lab and field, with the amplitude variations often >5%. The field-based variations are more severe and occur on both long-term (months) and short-term (hours) timescales. Short-term variability correlates with changes in environmental conditions and is considerable (up to 25%) for the Chaparral M50A and noticeable (∼5%) for the French Alternative Energies and Atomic Energy Commission (CEA) MB3a. Long-term magnitude variability for the Chaparral M50A was up to 50% and does not clearly correlate with environmental conditions. The other sensors show some long-term magnitude offsets, but they have relatively stable responses in the conditions we examined. The MB3a also displays some frequency-dependent magnitude variability and shows a minor dependence on temperature. Phase estimates are stable and near zero for all sensors tested. These results strongly suggest sensor response and variability due to environmental conditions should be considered in future infrasound data interpretation and sensor selection and development.

Fee, David↗