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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

2018 Report on Rare Plant Monitoring and Restoration at the Lawrence Livermore National Laboratory’s Experimental Test Site (Site 300)

This document meets the reporting requirements of LLNL’s California Endangered Species Act Scientific, Educational, or Management Permit (No. 2081 (a)-15-005-RP) for 2018. Section A describes monitoring and field activities conducted by LLNL biologists at the Site 300 native and experimental populations and the Carnegie Canyon native population of the federally-endangered plant, Amsinckia grandiflora (the large-flowered fiddleneck), between January 2018 and December 2018. In addition, monitoring and field activities conducted by LLNL biologists at the Site 300 native populations of the rare plants Eschscholzia rhombipetala (the diamond-petaled California poppy) and Blepharizonia plumosa (the big tarplant) between January 2018 and December 2018 are described in Sections B and C, respectively. Both plants have a California Rare Plant Rank (CRPR) of 1B, which includes species that are rare or endangered throughout their range. California macrophylla (the round-leaved filaree), formerly had a CRPR of 1B, but was downgraded to CBR (Considered But Rejected) in December 2017, as the species was “too common statewide: counties that contain small, localized populations under severe threat should track C. macrophylla as a species of local concern” (California Native Plant Society, 2018). As C. macrophylla is widespread at Site 300 (Carlsen and Paterson, 2018), 2018 will be the final year of monitoring C. macrophylla at Site 300, the results of which are described in Section D. Monitoring of the Navarretia nigelliformis ssp. radians (adobe navarretia), a CRPR 1B species, is planned, and results will be included in future reports.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Cavern Leaching Monitoring CY18 And CY19

The U.S. Strategic Petroleum Reserve (SPR) is a crude oil storage system run by the U.S. Department of Energy (DOE). The reserve consists of 60 active storage caverns spread across four sites in Louisiana and Texas, near the Gulf of Mexico. Beginning in 2016, the SPR began executing U.S. congressionally mandated oil sales. The configuration of the reserve, with a total capacity of greater than 700 MMB, requires raw water to be used instead of saturated brine for oil withdrawals such as for sales. All sales will produce leaching within the caverns used for oil delivery. Thirty-six caverns had a combined total of over 29 MMB of water injected from CY18-CY19 for mandatory sales. Leaching effects were monitored in these caverns to understand how the sales operations may impact the long-term integrity of the caverns. While frequent sonars are the best way to monitor changes in cavern shape, they can be resource intensive for the number of caverns involved in sales and exchanges. An intermediate option is to model the leaching effects and see if any concerning features develop. The leaching effects were modeled here using the Sandia Solution Mining Code (SANSMIC). The results indicate that leaching induced features are not of concern in the majority of the caverns, 32 of 36. Four caverns, BH-107, BH-108, BH-114 and WH-114 have features that may grow with additional leaching and should be monitored as leaching continues in those caverns. Six caverns had post sale sonars which were compared with SANSMIC results. SANSMIC was able to capture the leaching well. A deviation in the SANSMIC and sonar cavern shapes was observed near the cavern floor in caverns with significant floor rise, a process not captured by SANSMIC. These results suggest SANSMIC is a useful tool for monitoring changes in cavern shape due to leaching effects related to sales and exchanges.

02 PETROLEUM↗
DOE OSTI2021

Strategic Petroleum Reserve Cavern Leaching Monitoring CY20

The U.S. Strategic Petroleum Reserve is a crude oil storage system run by the U.S. Department of Energy. The reserve consists of 60 active storage caverns spread across four sites in Louisiana and Texas, near the Gulf of Mexico. Beginning in 2016, the SPR began executing U.S. congressionally mandated oil sales. The configuration of the reserve, with a total capacity of greater than 700 MMB, requires raw water to be used instead of saturated brine for oil withdrawals such as for sales. All sales will produce leaching within the caverns used for oil delivery. Twenty-five caverns had a combined total of over 39 MMB of water injected in CY 20 as part of the Exchange for Storage program; oil was withdrawn in the same manner as for congressionally mandated sales. Leaching effects were monitored in these caverns to understand how the oil withdrawals may impact the long-term integrity of the caverns. While frequent sonars are the best way to monitor changes in cavern shape, they can be resource intensive for the number of caverns involved in sales and exchanges. An intermediate option is to model the leaching effects and see if any concerning features develop. The leaching effects were modeled here using the Sandia Solution Mining Code (SANSMIC) . The results indicate that leaching induced features are not of concern in the majority of the caverns, 19 of 25. Six caverns, BH-107, BH-113, BH-114, BM-4, BM-106, and WH-114 have features that may grow with additional leaching and should be monitored as leaching continues in those caverns. Ten caverns had post sale sonars that were compared with SANSMIC results. SANSMIC was able to capture the leaching well , particularly the formation of shelves and flares. A deviation in the SANSMIC and sonar cavern shapes was observed near the cavern floor in caverns with significant floor rise, a process not captured by SANSMIC. These results suggest SANSMIC is a useful tool for monitoring changes in cavern shape due to leaching effects related to sales and exchanges.

02 PETROLEUM↗
DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine

03 NATURAL GAS↗
DOE OSTI2022

Automation of Plot Generation for Strategic Petroleum Reserve Cavern Leaching Monitoring

Monitoring cavern leaching after each calendar year of oil sales is necessary to support cavern stability efforts and long-term availability for oil drawdowns in the U.S. Strategic Petroleum Reserve. Modeling results from the SANSMIC code and recent sonars are compared to show projected changes in the cavern’s geometry due to leaching from raw-water injections. This report aims to give background on the importance of monitoring cavern leaching and provide a detailed explanation of the process used to create the leaching plots used to monitor cavern leaching. In the past, generating leaching plots for each cavern in a given leaching year was done manually, and every cavern had to be processed individually. A Python script, compatible with Earth Volumetric Studio, was created to automate most of the process. The script makes a total of 26 plots per cavern to show leaching history, axisymmetric representation of leaching, and SANSMIC modeling of future leaching. The current run time for the script is one hour, replacing 40-50 hours of the monitoring cavern leaching process.

02 PETROLEUM↗
DOE OSTI2022

Quantifying Nitrogen Bioextraction by Seaweed Farms – A Real-time Modeling-Monitoring Case Study in Hood Canal, WA

Anthropogenic nitrogen input is the leading cause of increasing marine eutrophication. Cultivating seaweeds at large scales may provide a viable solution for mitigating eutrophication especially when nitrogen extraction is achieved as an added environmental benefit of biofuel and food production. As the first step to promoting and implementing this solution, it is critical to quantify and assess the effectiveness of nitrogen removal by existing seaweed farms. Pacific Northwest National Laboratory and Hood Canal Mariculture Inc. conducted a case study by applying a coupled modeling-monitoring approach to quantify nitrogen bioextraction by a one-hectare commercial sugar kelp farm in Hood Canal, WA. Through this two-year effort, the project team conducted intensive field monitoring of water quality parameters at the farm site and subsequent laboratory analysis. Meanwhile, the team applied a coupled hydrodynamic-macroalgal growth model to simulate kelp growth and nitrogen bioextraction over the two kelp growing seasons. The model results showed an overall good comparison with field monitoring data and showed the effectiveness of nitrogen removal by kelp farms. The established modeling-monitoring approach can also be transferable for supporting broader research activities in macroalgal farming and eutrophication mitigation.

09 BIOMASS FUELS↗
DOE OSTI2022

Integrated Monitoring of Macroalgae Farms Using Acoustics and UUV Sensing

The vision of this project was to develop an integrated system for autonomous underwater vehicle (AUV) monitoring of offshore kelp farms using acoustic, environmental, and optical sensors. This project supports the overall MARINER goals of developing an offshore kelp aquaculture industry to produce low-carbon or carbon-neutral biofuels. The project commenced in the spring of 2018 and used laboratory experiments to test the efficacy of acoustic sensors for monitoring kelp farm lines and growing kelp biomass. Sensors were then integrated onto two AUVs as well as an autonomous surface vehicle in order to establish the optimal type, price point, and vehicle to most efficiently monitor kelp farm structures, kelp biomass, and the surrounding environment. Multiple field deployments of these vehicles and sensors in Massachusetts, New Hampshire, and Maine confirmed that farm lines and kelp could be visualized and that monitoring the spatial patterns of environmental variables was possible. The COVID-19 pandemic severely limited fieldwork activities and laboratory testing, with deployments around kelp farms not occurring again until January 2021. Time spent away from the field focused on data visualization and the development of a low-cost, vessel-based sensor system. Unfortunately, the low-cost system experienced a disk failure during its first deployment and due to multiple resignations from the project team further engineering and development was not possible. Additionally, final results from acoustic sensor testing in 2021 were also not able to be completed due to the resignation of the postdoc leading the analysis. Despite these setbacks, multiple avenues for further development of optical imagery processing from the 360-degree Kelpcam camera and testing of the low-cost sensor system may be possible.

09 BIOMASS FUELS↗
DOE OSTI2022

Strategic Petroleum Reserve Cavern Leaching Monitoring CY21

Th e U.S. Strategic Petroleum Reserve (SPR) is a crude oil storage system administered by the U.S. Department of Energy. The reserve consists of 60 active storage caverns located in underground salt domes spread across four sites in Louisiana and Texas, near the Gulf of Mexico. Beginning in 2016, the SPR started executing C ongressionally mandated oil sales. The configuration of the reserve, with a total capacity of greater than 700 million barrels ( MMB ) , re quires that unsaturated water (referred to herein as ?raw? water) is injected into the storage caverns to displace oil for sales , exchanges, and drawdowns . As such, oil sales will produce cavern growth to the extent that raw water contacts the salt cavern walls and dissolves (leaches) the surrounding salt before reaching brine saturation. SPR injected a total of over 45 MMB of raw water into twenty - six caverns as part of oil sales in CY21 . Leaching effects were monitored in these caverns to understand how the sales operations may impact the long - term integrity of the caverns. While frequent sonars are the most direct means to monitor changes in cavern shape, they can be resource intensive for the number of caverns involved in sales and exchanges. An interm ediate option is to model the leaching effects and see if any concerning features develop. The leaching effects were modeled here using the Sandia Solution Mining Code , SANSMIC . The modeling results indicate that leaching - induced features do not raise co ncern for the majority of the caverns, 15 of 26. Eleven caverns, BH - 107, BH - 110, BH - 112, BH - 113, BM - 109, WH - 11, WH - 112, WH - 114, BC - 17, BC - 18, and BC - 19 have features that may grow with additional leaching and should be monitored as leaching continues in th ose caverns. Additionally, BH - 114, BM - 4, and BM - 106 were identified in previous leaching reports for recommendation of monitoring. Nine caverns had pre - and post - leach sonars that were compared with SANSMIC results. Overall, SANSMIC was able to capture the leaching well. A deviation in the SANSMIC and sonar cavern shapes was observed near the cavern floor in caverns with significant floor rise, a process not captured by SANSMIC. These results validate that SANSMIC continues to serve as a useful tool for mon itoring changes in cavern shape due to leaching effects related to sales and exchanges.

02 PETROLEUM↗
DOE OSTI2023

2022 Long-Term Hydrologic Monitoring Program Report for the Rio Blanco, Colorado Site

This report presents the monitoring data collected by the U.S. Department of Energy (DOE) Office of Legacy Management (LM) during the 2022 sampling event at the Rio Blanco, Colorado, Site, where an underground nuclear test was conducted in 1973. The test resulted in residual radionuclide contamination at the detonation depth. The 2022 sampling event included the collection of samples from onsite groundwater wells to monitor for any potential contamination that might be attributed to the Rio Blanco nuclear tests. This report summarizes the laboratory results obtained from the sampling along with the historical results since monitoring began in the 1970s. This annual report and previous reports are available on the LM public website at https://www.energy.gov/lm/rio-blanco-colorado-site. Data collected during this and previous monitoring events are available on the Geospatial Environmental Mapping System (GEMS) website at https://gems.lm.doe.gov/#site=RBL.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Final Report DE-FE0031785 Mohsen Ahmadian, Ph.D. Demonstration of Proof of Concept of a Multiphysics Approach for Real-Time Remote Monitoring of Dynamic Changes in Pressure and Salinity in Hydraulically Fractured Networks

Hydraulic fracturing has evolved into a multistep process with varying flow rates, carrier fluids (e.g., gel or slickwater), proppant loadings, and proppant grain sizes. As a result, primary recovery from a hydraulically fractured tight-oil reservoir is often a tiny fraction of the original oil in place, ranging between 5 and 10%. As stated in the FOA1990, “part of this problem is due to the inability of current well completion processes to effectively stimulate the entire reservoir volume in contact with the wellbore. Innovative technologies are needed that can help improve the effectiveness of reservoir completion methods, maximize stimulated reservoir volumes, and optimize recovery over the entire producing life span of a well”. We first need to enhance the current fracture diagnostic techniques to improve a well-completion design. However, detecting and delineating a subsurface hydraulic fracture is extremely difficult because the induced fracture network is only fractionally propped, and these propped fractures are generally very thin. Microseismic and tiltmeter monitoring techniques can provide information on the fracture extent but provide little or no information on the movement and final distribution of proppant or production fluids. On the other hand, electromagnetic (EM) imaging has shown the capability to monitor proppant distribution throughout the fracture area, especially in the presence of Electrically Active Proppants (EAPs). A previous EM survey of hydraulic fracturing at the Devine Fracture Pilot Site (DFPS) and subsequent EM code developments demonstrated this survey as a robust technique to remotely interrogate the extent of the EAP-filled hydraulic fracture during its propagation. The objectives of the project were threefold: (1) to capitalize on the material properties of an EAP to demonstrate remote monitoring of relative changes in pressure, pressure, and flow that are commonly encountered during production from a hydraulically fractured reservoir; (2) to evaluate EM imaging tools, to achieve Objective 1 in near real-time; and (3) to develop a multi-physics joint inversion approach to precisely predict flow patterns and physiochemical changes within an EAP-filled fracture network. This research project was built upon our previous work at the Devine Test Site managed by the Bureau of Economic Geology (BEG) at The University of Texas at Austin (UT-Austin). It also leveraged a significant investment from the Advanced Energy Consortium (AEC) to address the DOE's interest in subsurface flow, containment, and characterization by multiple signals. This three-year and three-month project succeeded in demonstrating the feasibility of a real-time dynamic fluid flow mapping technique at Technology Readiness Level 5 (TRL5) by utilizing a commercially available surface-based Controlled-Source Electromagnetic (CSEM) method (Objectives 1, 2). We demonstrated that injections into an EAP-filled fracture could be successfully coupled with real-time electric field measurements on the surface, leading to remote monitoring of dynamic changes within the EAP-filled fracture. Furthermore, the observed electric field in our study is influenced by bottomhole pressure, flow rate, and salinity, which is demonstrated by comparing these parameters with the electrical field potentials. EM simulations solely based on assumptions of fracture conductivity changes during injection did not reproduce the whole measured electric field magnitudes. Preliminary estimates showed that including Streaming Potential (SP) in our geophysical model is likely needed to reduce the simulation misfit.

02 PETROLEUM↗
DOE OSTI2021

2019 Groundwater Monitoring Report Project Shoal Area: Subsurface Corrective Action Unit 447

The Project Shoal Area is a site in Nevada where an underground nuclear test was conducted in 1963. It later came to be known as the Shoal, Nevada, Site. Surface contamination at the site has been remediated, but investigation of groundwater contamination resulting from the test is still in the corrective action process. Annual sampling and water-level monitoring are conducted as part of the subsurface corrective action strategy, which has focused on revising the site conceptual model and evaluating the adequacy of the monitoring well network. It has also included enhancements to the monitoring well network to address uncertainties in the groundwater flow direction and the cause of rising water levels in site wells west of the shear zone since the first hydrologic characterization (HC) wells were installed in 1996. Revisions to the site conceptual model and enhancements to the monitoring strategy were provided to Nevada Division of Environmental Protection (NDEP) in the Addendum to: Corrective Action Decision Document/Corrective Action Plan (CADD/CAP) for the Subsurface Corrective Action Unit 447 Shoal, Nevada, Site. NDEP approved the addendum to the CADD/CAP, which included an expanded contaminant boundary and compliance boundary for the site.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Combustion Performance and Emissions Optimization Through Integration of a 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, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2023

Online Monitoring Applications Enabled by Phasor Measurement Units: Technical Assistance to the Power Sectors of Southeast Asia

In this report, an overview of several online applications enabled by PMU measurements is provided. Besides a brief technical background for each application, the report also discusses control room displays and alarming methodologies used by North American organizations, and applicable standards set by the North American Electric Reliability Corporation (NERC). The five applications discussed herein are inertia monitoring, linear state estimation, voltage stability monitoring, small-signal stability monitoring, and forced oscillation monitoring.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Combustion Performance and Emissions Optimization through Integration 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. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, 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 can be 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, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2022

Combustion Performance and Emissions Optimization Through Integration of a 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. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, 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 can be 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, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
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 OSTI2023

Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays

This is the final technical report for the Virginia Tech Center for Photonics Technology (VT-CPT) research project entitled “Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays”. In the the four-year effort, VT-CPT collaborated with the Departments of Mathmatics at VT and Sentek Instrument, LLC (Sentek) to develop a fiber-optic sensing system capable of real-time simultaneous distributed measurement of multiple subsurface, drilling, and production parameters. The ultra-sensitive fiber optic distributed acoustic sensing technology, picoDAS, developed by Sentek was integrated with a novel multi-material optical sensing fiber fabricated by CPT-VT to obtain distributed acoustic and magnetic field measurements with ultrahigh sensitivity and high spatial resolution. The sensing technology successfully developed and demonstrated under this research program is truly unique has application beyond subsurface imaging to include carbon storage and electrical grid monitoring, as well as healthcare and nuclear fusion. The project, sponsored by the Advanced Technology Program, began in 2019 and had the original goal of developing the next generation of harsh environment sensing systems. Exhaustive theoretical modeling was performed to optimize the multi-material optical fiber design. VT developed the processing techniques employed to successfully fabricate single mode fibers with metal cladding wires. Sensing fibers with nickel and Metglas cladding wires were fully characterized, inscribed with sensors, and fully integrated with the picoDAS system. Laboratory scale testing was performed to demonstrate performance upon exposure to lateral and transverse magnetic fields. Preliminary field trials were performed for prototype magnetic and acoustic sensing systems upon near surface deployment at VT. The distributed acoustic and magnetic field sensing system was advanced from a (Technology Readiness Level) TRL=2 to a TRL=5 via laboratory scale system validation in relevant environments. The truly one-of-its kind distributed magnetic and acoustic sensing system is expected to find immediate applications that require subsurface monitoring, to include carbon storage site monitoring, and has the potential to be a distributive technology in healthcare and electric grid markets. The technologies developed by Virginia Tech’s Center for Photonics Technology will support the mission of the National Energy Technology Laboratory (NETL) to drive innovation and deliver solutions for an environmentally sustainable and prosperous energy future by ensuring affordable, abundant, and reliable energy that drives a robust economy and national security. Technical accomplishments during the program are summarized briefly here and described in detail in the remainder of the report.

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