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DOE OSTI2022

Embedded acoustic sensing and monitoring techniques for small modular reactors

The goal of this project was to study the applicability of specific innovative instrumentation techniques for assessing parameters needed for safe small modular reactor operation and safeguarding of nuclear material. Small modular reactor core designs are currently being developed to provide energy more effectively and efficiently than in the past because they can be built as modules at fabrication sites and then transported to a power-producing facility. However, these modules and/or the final core will often be sealed and not accessible again until disposal. Instead of instruments that access the core directly, during and after operation, to monitor flux/dose and structural integrity, as current power plants use, new sensors need to be designed that can be built into the reactor initially to determine operating history, structural integrity through operation of the system, and nuclear material accountancy after shutdown and before disposition of the core. Embedded sensors already exist that can provide neutron flux, gamma dose, and temperatures, but techniques to expand upon these for assessing structural health and material inventory in the system over time need to be developed. Structural health assessments include the detection and imaging of cracks in the components that could eventually cause radioactive fission products to be released.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Advanced Distributed Optical Fiber Sensor Systems for Pipeline Integrity Monitoring

Distributed fiber optic sensors allow the measurement of structural parameters such as static/dynamic strain, temperature, pressure, and vibrations at thousands of locations along a single fiber cable. Deep neural network (DNN) algorithms were developed for rapid data processing speed and vibration event classification.

Lalam, Nageswara↗

DOE OSTI2022

Fiber-optic diagnostic system for future accelerator magnets

The next generation high energy physics accelerators will require magnetic fields at ~20 T. HTS coils will be an essential component of future accelerator magnets and several efforts are currently dedicated on designing 20 T HTS- LTS hybrid magnets. Among the existing challenges, there is the lack of a robust quench detection system for hybrid magnet technology. Another big challenge is represented by the high number of training quenches required by Nb3Sn magnets to reach performance level. In this framework it is important to find a tool that allow local real-time monitoring of magnet strain and temperature. In this paper, we propose the use of fiber optics sensors for diagnostic and quench detection in future accelerator superconducting magnets. Discrete and distributed fiber optic sensors have demonstrated to be a promising tool. The goal is to instrument hundreds of accelerator superconducting magnets and to move beyond the proof-of-concept level. Significant developments are still needed. Here, we are going to present the most recent results and discuss the most urgent technical developments in order to make those sensors a robust and reliable diagnostic tool for accelerator superconducting magnets over the next 10 year. We foresee that discrete fiber sensors will be a stable diagnostic probe for superconducting magnets over the next 3 to 5 years. More R&D work will be necessary for distributed fibers. The most urgent needs are the increase of sample rate and sensitivity. Close collaboration with vendors will be necessary to improve mechanical properties and fabrication processes in order to produce hundreds of meters of fiber and instrument a large number of accelerator superconducting magnets. Those R&D efforts will last up to 10 years with a founding level that spans between 5-10 M$.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

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 of wall conditions in utility boilers. 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 a coal-fired utility boiler 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.

42 ENGINEERING↗

DOE OSTI2024

Enhanced Bottom Anode Monitoring in DC Electric Arc Furnaces Using Fiber-Optic Sensors

A pin style bottom anode employs conductive steel rods that serve as the pathway for the high electrical power through rammed refractory at the bottom of a DC Electric Arc Furnace (EAF). Anode wear during operation is important to monitor, as anode replacement is expensive and impacts EAF productivity. Liquid steel penetration into the un-sintered refractory layer can result from rapid electrical power ramp-up, dips in furnace temperature, or operating the anode for too long between EAF campaigns. In extreme cases, the liquid steel may penetrate the bottom of the furnace when anode wear progresses too close to the bottom shell, which is extremely dangerous and must be avoided. The current state of the art for monitoring bottom anode wear employs thermocouples imbedded in the anode pins at points in the anode. However, this approach is not sensitive enough to detect localized damage to the anode, especially when cracking occurs. Here, the present work utilizes fiber optic sensors to monitor the health of the anode, by creating a real-time spatially distributed temperature map of the anode. Unlike the traditional thermocouples, these sensors can be mounted at significantly greater depths, provide distributed temperature measurements, and can withstand temperatures of up to 900°C. Additionally, they are able to perform temperature measurements with a spatial resolution of 1.3 mm at a 5 Hz acquisition rate, providing unprecedented high-density real time monitoring of anode health and increasing the efficiency, and safety of EAF operation.

Bottom Anode↗

DOE OSTI2021

All-aerosol-jet-printed highly sensitive and selective polyaniline-based ammonia sensors: a route toward low-cost, low-power gas detection

In this work, we report the design and scalable fabrication of a low-cost and low-power polyaniline-based (PANI) ammonia (NH3) gas sensor on polyimide (PI) substrates using additive manufacturing techniques. The silver interdigitated electrode (IDE) arrays and conducting polymer films are printed onto PI using a direct-write technology of aerosol-jet printing. Morphological characteristics are examined by scanning electron microscopy and energy-dispersive X-ray analysis which reveal homogeneously printed PANI film on the IDE platform. The gas sensing performance is evaluated in the analytical early leak detection range of 5–1000 ppm NH3 in air as a function of both thermal (23 °C, 50 °C, 80 °C) and relative humidity (RH = 0%, 30%, 50%) exposures. The sensor exhibits sensitivity down to 5 ppm NH3 with a sub-ppm detection limit and good repeatability. We observe rapid NH3 detection at 0% RH with very extended times for equilibration and recovery. However, at both 30 and 50% RH, the room temperature response and recovery times are reduced to only about 1 min and 5 min, respectively. Experiments also reveal good sensitivity toward the analyte even at higher operating temperatures. Present results merit the practical application of aerosol-jet-printed, low-power sensors for industrial applications where low-level hazardous gas detection is essential.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Combined Mesonet and Tracker

Title: Combined Mesonet and Trackers (UNL Mobile Mesonets) Authors University of Nebraska PI: Adam Houston, UNL Professor (ahouston2@unl.edu) Mailing Address: 126 Bessey Hall P.O. Box 880340 Lincoln, NE 68588-0340 CoMeT Overview The University of Nebraska-Lincoln operates three Combined Mesonet and Tracker (CoMeTs). CoMeTs are Ford Explorers (model years 2015, 2017, and 2019) with forward-mounted suites of meteorological sensors and dual moonroofs, combining the capability of a mobile mesonet to collect near-surface observations with the capability of an unmanned aircraft systems (UAS) tracker vehicle, which enables an observer in the second row of seats to see the aircraft and maintain compliance with Federal Aviation Administration policies on UAS operation. The CoMeTs collect observations of slow temperature and humidity at ~2 m above ground level (AGL) using a Vaisala HMP155A, fast temperature at ~2 m AGL using a Campbell Scientific 109SS-L thermistor, pressure at ~2.5 m AGL using a Vaisala PTB210, wind speed and direction at ~3.25 m AGL using an R.M. Young 05103 propeller anemometer, and vehicle heading using a KVH Industries C-100 fluxgate compass (Barbieri et al. 2019). The HMP155A and 109SS-L thermistor are shielded and aspirated within a U-tube (Waugh and Frederickson 2010; Houston et al. 2016). This list of sensors is also included in the CoMeT data file metadata. Manufacturer specifications for these instruments are given in Table 1 of Hanft and Houston (2018). The reported measured quantities are summarized below.CoMeT-3 was funded through an equipment allocation included in the NSF TORUS award (AGS-1824649). Instrument Description The specific sensors included on each CoMeT are summarized in the table at the end of this section. In general each CoMeT collects observations of slow temperature and humidity at ~2 m above ground level (AGL) using a Vaisala HMP155, fast temperature at ~2 m AGL using a Campbell Scientific 109SS-L thermistor, pressure at ~2.5 m AGL using a Vaisala PTB210 barometer with a Gill pressure port, wind speed and direction at ~3.25 m AGL using an R.M. Young 05103 propeller anemometer, position using a Garmin 19x HVS receiver, and vehicle heading using a KVH Industries C-100 fluxgate compass. The HMP155 and 109SS are shielded and aspirated within a U-tube (Waugh and Frederickson 2010; Houston et al. 2016). Fast temperature and corrected RH measurements (using sensors housed within the U-tube) have a time constant of 10-12 s based on data collected across a temperature and RH shock during the CLOUD-MAP 2017 calibration/validation tests on June 26, 2017. Vehicle speed was < 10 kts for this test. CoMeT-1 CoMeT-2 CoMeT-3 Slow Temperature Slow RH Vaisala HMP155A-L20-PT Part #: 22280-7 Vaisala HMP155E Part #: E1AA11A0B1A1A0A Vaisala HMP155E Part #: E1AA11A0B1A1A0A Fast temperature Campbell Scientific 109SS-L20-PT Part #: 21448-3 Campbell Scientific 109SS-L12-PW Part #: 21448-109 Campbell Scientific 109SS-L12-PW Part #: 21448-150 Pressure Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Wind RM Young 05103-L20-PT Part #: 18435-310 RM Young 05103-L20-PW Part #: 18435-244 RM Young 05103-L20-PW Part #: 18435-244 GPS Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Compass KVH C-100 Part #: 01-0177-15 KVH C-100 Part #: 01-0177-15 KVH C-100 Part #: 01-0177-15 Logger Campbell Scientific CR6-NA-XT-SW Part #: 28385-9 Campbell Scientific CR6-WIFI-XT-SW Part #: 28385-6 Campbell Scientific CR6-WIFI-XT-SW Part #: 28385-6 Data Collection and Real-Time Processing The reported measured quantities are summarized in the table below. Quantity Units Source Epoch time Seconds GPS Latitude and longitude Degrees GPS Altitude m GPS Pressure hPa PTB210 Temperature (fast) deg C 109SS-L Temperature (slow) deg C HMP155 RH (slow) % HMP155 Vehicle speed m/s GPS Vehicle heading deg C-100 and GPS In addition to the measured variables, several derived variables are calculated. Corrected/fast relative humidity (%) Relative humidity is adjusted to the fast temperature following Richardson et al. (1998) and Houston et al. (2016). Water vapor mixing ratio (g/kg) Dew point temperature (°C) Potential temperature (Kelvin) Virtual potential temperature (Kelvin) Equivalent potential temperature (Kelvin) Regular intercomparisons between all three CoMeTs were performed during TORUS 2019. Comparisons were also conducted between CoMeT-1 and CoMeT-2 during LAPSE-RATE (2018) on 14 July. In these intercomparisons, the vehicles were parked adjacent to each other aligned perpendicular to (and facing into) the wind. To minimize engine heating effects, intercomparisons were only conducted when the wind speed was >10 kts. Data Format Original data files for each deployment are saved as text files and then converted to NetCDF. NetCDF versions have units that are CF compliant and may not match the original units in the txt files. The naming convention for the NetCDF files is as follows: UNL.CoMeT3.{deployment date YYYYMMDD}.{start time of observation collection in UTC HHMM}.L2.{post-processing codes}.cdf example: UNL.CoMeT3.20190627.1931.L2.g1.f1.cdf Post-processing codes are included to track modifications to the raw data. These codes are closely connected to error flags associated with each record. Each letter corresponds to a particular instrument: g: GPS p: Barometer tf: Fast temperature ts: Slow temperature rh: Relative humidity f: Compass w: Wind monitor a: All instruments Each number corresponds to a particular post-processing action described more below. Measured and derived variables are included in the following table. Variable Heading Standard Name Units time Time seconds since 00:00:00, 01-01-1970 Alt Altitude meters lat Latitude degrees north lon Longitude degrees east fast_temp Air Temperature kelvin slow_temp Air Temperature kelvin pressure Air Pressure pascals logger_RH Relative Humidity percent calc_corr_RH Relative Humidity percent wind_speed Wind Speed meters per second wind_dir Wind From Direction degrees vehicle_dir Vehicle Direction degrees dewpoint Dew Point Temperature kelvin mixing_ratio Humidity Mixing Ratio g/g theta Air Potential Temperature kelvin theta_v Virtual Potential Temperature kelvin theta_e Equivalent Potential Temperature Kelvin error_flag The error_flag variable is a string that matches the post-processing codes listed above. All instruments will have an associated code, but will have a “0” if the datum is unchanged from the initial processed value. Error Codes The following table summarizes the error codes for data collected before 2020: Error Code Relevant CoMeT Description g1 1,2,3 Exact correction. GPS position and time reprocessed from raw data g2 1 As far as we can tell this is an exact correction to an error in the GPS time. During the correct time periods the time suddenly went backwards ~250s and stayed at this offset for 750s when it corrected itself. The offset was applied to the “time warp” period. p1 2 Approximate correction. Hole in the pressure tube connecting the pressure port to the barometer. Resulted in erroneously low air pressure measurements when the vehicle was in motion. Derived variables recalculated (dew point temperature [e depends on qv and p], water vapor mixing ratio, potential temperature, virtual potential temperature, equivalent potential temperature) a1 3 Exact correction. Missing data reprocessed from raw data a2 1 Bug fix to bias correction for ts1, ts2, and rh1: water vapor mixing ratio was off by a factor of 10 and virtual potential temperature was wrong because of this. f1 3 No correction, missing data. Fluxgate compass inoperable. Wind speed and direction calculated using GPS-derived vehicle heading instead. rh1 1 Approximate correction. Constant bias of +1.7% removed from relative humidity. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) ts1 1 Approximate correction. Constant bias of +0.6 K removed from slow temperature. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) ts2 1 Approximate correction. Constant bias of +1.0 K removed. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) References Bolton, D., 1980: The Computation of Equivalent Potential Temperature. Mon. Wea. Rev., 108, 1046–1053, https://doi.org/10.1175/1520-0493(1980)108<1046:TCOEPT>2.0.CO;2. Hanft, W., and A. L. Houston, 2018: An Observational and Modeling Study of Mesoscale Air Masses with High Theta-E. Mon. Wea. Rev., 146, 2503–2524, https://doi.org/10.1175/MWR-D-17-0389.1.Wexler Houston, A. L., R. J. Laurence III, T. W. Nichols, S. Waugh, B. Argrow, and C. L. Ziegler, 2016: Intercomparison of unmanned aircraft-borne and mobile mesonet atmospheric sensors. Journal of Atmospheric and Oceanic Technology. 33, 1569-1582, doi: 10.1175/JTECH-D-15-0178.1. Lowe, P. R., 1977: An Approximating Polynomial for the Computation of Saturation Vapor Pressure. J. Applied Meteorology, 16, 100–103. Richardson, S. J., S. E. Frederickson, F. V. Brock, and J. A. Brotzge, 1998: Combination temperature and relative humidity probes: Avoiding large air temperature errors and associated relative humidity errors. Preprints, 10th Symp. On Meteorological Observations and Instrumentation, Phoenix, AZ, Amer. Meteor. Soc., 278–283. Waugh, S., and S. E. Frederickson, 2010: An improved aspirated temperature system for mobile meteorological observations, especially in severe weather. 25th Conf. on Severe Local Storms, Denver, CO, Amer. Meteor. Soc., P5.2. [Available online at https://ams.confex.com/ams/25SLS/techprogram/paper_176205.htm.]

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 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 OSTI2022

An in-situ conductometric apparatus for physicochemical characterization of solutions and in-line monitoring of separation processes at elevated temperatures and pressures

Specific conductance and frequency-dependent resistance (impedance) data are widely utilized for understanding the physicochemical characteristics of aqueous and non-aqueous fluids and for evaluating the performance of chemical processes. However, the implementation of such an in-situ probe in high-temperature and high-pressure environments is not trivial. This work provides a description of both the hardware and software associated with implementing a parallel-type in-situ electrochemical sensor. The sensor can be used for in-line monitoring of thermal desalination processes and for impedance measurements in fluids at high temperature and pressure. Further, a comparison between the experimental measurements on the specific conductance in aqueous sodium chloride solutions and the conductance model demonstrate that the methodology yields reasonable agreement with both the model and literature data. A combination of hardware components, a software-based correction for experimental artifacts, and computational fluid dynamics (CFD) calculations used in this work provide a sound basis for implementing such in-situ electrochemical sensors to measure frequency-dependent resistance spectra.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Assessment of Acoustic Sensor Application to Structural Health Monitoring of Reactor Components

The objectives of SHM of advanced fission reactors include the following: (1) Maintain safe, reliable, and efficient operation of structures, systems, and components in accordance with design intent; (3) Reduce cost; (4) Improve the comprehensive life management of structures, systems, and components; and (5) Extend the operational life of a power system through retirement for cause. Advanced reactor designs currently being considered are expected to operate at higher temperatures than light water-cooled reactors and to support missions beyond baseload electricity generation. Methods to monitor and detect for these mechanisms will require structural health monitoring (SHM) techniques, with ultrasonic methods an ideal candidate given their widespread use for NDE. This document summarized the state of technology for ultrasonic technologies, as part of an assessment of technology gaps and needed research. The great majority of sensor development to date addresses elevated temperatures and radiation tolerance, and more work is needed in both areas. Little data exists regarding corrosion effects of advanced coolants on sensor materials and couplants. Of high importance is the need for ARDs and regulatory bodies to engage and define what level of SHM is needed for autonomous or semi-autonomous control of reactors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Revolutionizing observations and predictability of Arctic system dynamics through next-generation dense, heterogeneous and intelligent wireless sensor networks with embedded AI

The Arctic region is a complex and dynamic system, where changes in temperature and partitioning between water in solid, liquid and vapor phase are fundamentally reshaping hydro-biogeochemical fluxes from the bedrock to the atmosphere. The increasing temperature and frequency of extreme heat, precipitation and fire events (Wang et al., 2017; Meredith et al., 2019) have critical consequences for the Arctic ecosystems and people, as well as for the global climate system. Although many observational and remote sensing activities have been on-going, detailed ecosystem processes – particularly related to controls on and impacts of permafrost thaw – are difficult to detect or measure. To improve the understanding and prediction of these extreme events and their consequences, we need a revolution in the way we collect ground-based observations from hillslope to pan-Arctic scales and couple them with satellite imagery and models to deliver rich, actionable, and scale-appropriate data.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Reliable operation of Cr 2 O 3 :Mg/ $β$-Ga 2 O 3 p–n heterojunction diodes at 600 °C

Beta gallium oxide (β-Ga 2 O 3 )-based semiconductor heterojunctions have recently demonstrated improved performance at high voltages and elevated temperatures and are, thus, promising for applications in power electronic devices and harsh environment sensors. However, the long-term reliability of these ultra-wideband gap (UWBG) semiconductor devices remains barely addressed and may be strongly influenced by chemical reactions at the p–n heterojunction interface. Here, we experimentally demonstrate operation and evaluate the reliability of Cr 2 O 3 :Mg/β-Ga 2 O 3 p–n heterojunction diodes during extended operation at 600 °C, as well as after 30 repeated cycles between 25 and 550 °C. The calculated pO 2 -temperature phase stability diagram of the Ga-Cr-O material system predicts that Ga 2 O 3 and Cr 2 O 3 should remain thermodynamically stable in contact with each other over a wide range of oxygen pressures and operating temperatures. The fabricated Cr 2 O 3 :Mg/β-Ga 2 O 3 p–n heterojunction diodes show room-temperature on/off ratios >104 at ±5 V and a breakdown voltage (V Br ) of -390 V. The leakage current increases with increasing temperature up to 600 °C, which is attributed to Poole–Frenkel emission with a trap barrier height of 0.19 eV. Over the course of a 140-h thermal soak at 600 °C, both the device turn-on voltage and on-state resistance increase from 1.08 V and 5.34 mΩ cm 2 to 1.59 V and 7.1 mΩ cm 2 , respectively. This increase is attributed to the accumulation of Mg and MgO at the Cr 2 O 3 /Ga 2 O 3 interface as observed from the time-of-flight secondary ion mass spectrometry analysis. These findings inform future design strategies of UWBG semiconductor devices for harsh environment operation and underscore the need for further reliability assessments for β-Ga 2 O 3 -based devices.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Safety Compliance Verification of Fuel Cell Electric Vehicle Exhaust

NREL has been developing compliance verification tools for allowable hydrogen levels prescribed by the Global Technical Regulation Number 13 (GTR-13) for hydrogen fuel cell electric vehicles (FCEVs). As per GTR-13, FCEV exhaust is to remain below 4 vol% H2 over a 3-second moving average and shall not at any time exceed 8 vol% H2 and that this requirement is to be verified with an analyzer that has a response time of less than 300 ms. To be enforceable, a means to verify regulatory requirements must exist. In response to this need, NREL developed a prototype analyzer that meets the GTR metrological requirements for FCEV exhaust analysis. The analyzer was tested on a commercial fuel cell electric vehicle (FCEV) under simulated driving conditions using a chassis dynamometer at the Emissions Research and Measurement Section of Environment and Climate Change Canada and FCEV exhaust was successfully profiled. Although the prototype FCEV Exhaust Analyzer met the metrological requirements of GTR-13, the stability of the hydrogen sensor was adversely impacted by condensed water in the sample gas. FCEV exhaust is at an elevated temperature and nearly saturated with water vapor. Furthermore, condensed water is present in the form of droplets. Condensed water in the sample gas can collect on the hydrogen sensing element, which would not only block access of hydrogen to the sensor but can also permanently damage the sensor. In the past year, the design of the gas sampling system was modified to mitigate against the transport of liquid water to the sensing element. Laboratory testing confirmed the effectiveness of the modified sampling system water removal strategy while maintaining the measurement range and response time required by GTR-13. Testing of the upgraded analyzer design on an FCEV operating on a chassis dynamometer is scheduled for the summer of 2021.

DIRECT ENERGY CONVERSION,HYDROGEN↗

DOE OSTI2020

In situ measurement of phase transformations and residual stress evolution during welding using spatially distributed fiber-optic strain sensors

Welding of high-strength steels can result in large tensile strains as the base metal and filler material cool from their molten state. To combat these large tensile strains, low-transformation-temperature (LTT) metal fillers have been proposed. These fillers undergo a martensitic phase transformation at a lower temperature which can ultimately reduce the tensile strain or can even introduce compressive strain adjacent to the weld metal. However, the process for optimizing the composition of the LTT material, as well as various weld parameters for each unique weld geometry, can be quite expensive, especially if the acceptance criterion requires using neutrons, x-ray beams, or destructive techniques to characterize residual stresses. This work describes a simple, low-cost method for quantifying residual stresses and phase transformations in situ during welding. Spatially distributed fiber-optic sensors were bonded to a cast iron plate, along with tack-welded thermocouples, to measure temperature and strain during multiple passes with LTT filler metals. Results show that the fiber-optic sensors can successfully resolve compressive strain adjacent to the weld region caused by the martensitic phase transformations in the LTT filler material.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Ultrasonic Transducer Irradiation Test Results

Ultrasonic technologies offer the potential for high accuracy and resolution in-pile measurement of a range of parameters, including geometry changes, temperature, crack initiation and growth, gas pressure and composition, and microstructural changes. Many Department of Energy-Office of Nuclear Energy (DOE-NE) programs are exploring the use of ultrasonic technologies to provide enhanced sensors for in-pile instrumentation during irradiation testing. For example, the ability of small diameter ultrasonic thermometers (UTs) to provide a temperature profile in candidate metallic and oxide fuel would provide much needed data for validating new fuel performance models. These efforts are limited by the lack of identified ultrasonic transducer materials capable of long term performance under irradiation test conditions. To address this need, the Pennsylvania State University (PSU) was awarded an Advanced Test Reactor National Scientific User Facility (ATR NSUF) project to evaluate the performance of promising magnetostrictive and piezoelectric transducers in the Massachusetts Institute of Technology Research Reactor (MITR) up to a fast fluence of at least 1021 n/cm2 . A multi-National Laboratory collaboration funded by the Nuclear Energy Enabling Technologies Advanced Sensors and Instrumentation (NEET ASI) program also provided initial support for this effort. This irradiation, which started in February 2014, is an instrumented lead test and real-time transducer performance data are collected along with temperature and neutron and gamma flux data. The irradiation is ongoing and will continue to approximately mid-2015. To date, very encouraging results have been attained as several transducers continue to operate under irradiation.

Daw, Joshua↗

DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer: Radio frequency (RF) assisted drying of paper and board

Conventional multi-cylinder drying of paper and board typically relies on both conductive drying from steam-heated cylinders and convective drying, where heated air flows over the paper web surface. Conduction primarily contributes to heat transfer, while convection is the main driver of mass transfer. However, conventional drying systems are heavily dependent on steam, usually powered by fossil fuels, and are often energy-inefficient with high levels of waste. Additionally, these surface-driven processes result in a lower percentage of energy absorption compared to the energy supplied, leading to significant energy losses. To improve this long-standing process, an experimental system was developed to investigate a process intensification approach involving the integration of Radio Frequency (RF) heating, a volumetric electromagnetic technology, alongside traditional conduction and convection drying methods. This study also emphasizes the use of sensors to continuously monitor key parameters such as moisture content, supply system temperatures, sample temperatures, air flows, and drying rates in real-time. The effect of RF as an auxiliary energy source in localized environments at varying moisture levels was explored to optimize industrial drying systems, quantify potential improvements, and provide insights for future studies. Experimental results from trials combining RF with convection and with the base case alternating conduction-convection drying processes are presented. It is shown that RF is a viable process intensification approach for paper drying improving the drying rate and energy intensity at higher moisture contents. These findings offer valuable insights for process intensification and contribute to the process development, modeling, and simulation of advanced paper drying techniques.

42 ENGINEERING↗