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NASA NTRS2006

Antenna Technologies for Future NASA Exploration Missions

NASA s plans for the manned exploration of the moon and Mars will rely heavily on the development of a reliable communications infrastructure on the surface and back to Earth. Future missions will thus focus not only on gathering scientific data, but also on the formation of the communications network. In either case, unique requirements become imposed on the antenna technologies necessary to accomplish these tasks. For example, surface activity applications such as robotic rovers, human extravehicular activities (EVA), and probes will require small size, lightweight, low power, multi-functionality, and robustness for the antenna elements being considered. Trunk-line communications to a centralized habitat on the surface and back to Earth (e.g., surface relays, satellites, landers) will necessitate wide-area coverage, high gain, low mass, deployable antennas. Likewise, the plethora of low to high data rate services desired to guarantee the safety and quality of mission data for robotic and human exploration will place additional demands on the technology. Over the past year, NASA Glenn Research Center has been heavily involved in the development of candidate antenna technologies with the potential for meeting these strict requirements. This technology ranges from electrically small antennas to phased array and large inflatable structures. A summary of this overall effort is provided, with particular attention being paid to small antenna designs and applications. A discussion of the Agency-wide activities of the Exploration Systems Mission Directorate (ESMD) in forthcoming NASA missions, as they pertain to the communications architecture for the lunar and Martian networks is performed, with an emphasis on the desirable qualities of potential antenna element designs for envisioned communications assets. Identified frequency allocations for the lunar and Martian surfaces, as well as asset-specific data services will be described to develop a foundation for viable antenna technologies which might address these requirements and help guide future technology development decisions.

Miranda, Felix A.↗

NASA NTRS1978

Hydrogen Generator

Another spinoff from spacecraft fuel cell technology is the portable hydrogen generator shown. Developed by General Electric Company, it is an aid to safer operation of systems that use hydrogen-for example, gas chromatographs, used in laboratory analysis of gases. or flame ionization detectors used as $ollution monitors. The generator eliminates the need for high-pressure hydrogen storage bottles, which can be a safety hazard, in laboratories, hospitals and industrial plants. The unit supplies high-purity hydrogen by means of an electrochemical process which separates the hydrogen and oxygen in distilled water. The oxygen is vented away and the hydrogen gas is stored within the unit for use as needed. GE's Aircraft Equipment Division is producing about 1,000 of the generators annually.

Source record↗

NASA NTRS2016

Reliability and Maintainability Analysis for the Amine Swingbed Carbon Dioxide Removal System

I have performed a reliability & maintainability analysis for the Amine Swingbed payload system. The Amine Swingbed is a carbon dioxide removal technology that has gone through 2,400 hours of International Space Station on-orbit use between 2013 and 2016. While the Amine Swingbed is currently an experimental payload system, the Amine Swingbed may be converted to system hardware. If the Amine Swingbed becomes system hardware, it will supplement the Carbon Dioxide Removal Assembly (CDRA) as the primary CO2 removal technology on the International Space Station. NASA is also considering using the Amine Swingbed as the primary carbon dioxide removal technology for future extravehicular mobility units and for the Orion, which will be used for the Asteroid Redirect and Journey to Mars missions. The qualitative component of the reliability and maintainability analysis is a Failure Modes and Effects Analysis (FMEA). In the FMEA, I have investigated how individual components in the Amine Swingbed may fail, and what the worst case scenario is should a failure occur. The significant failure effects are the loss of ability to remove carbon dioxide, the formation of ammonia due to chemical degradation of the amine, and loss of atmosphere because the Amine Swingbed uses the vacuum of space to regenerate the Amine Swingbed. In the quantitative component of the reliability and maintainability analysis, I have assumed a constant failure rate for both electronic and nonelectronic parts. Using this data, I have created a Poisson distribution to predict the failure rate of the Amine Swingbed as a whole. I have determined a mean time to failure for the Amine Swingbed to be approximately 1,400 hours. The observed mean time to failure for the system is between 600 and 1,200 hours. This range includes initial testing of the Amine Swingbed, as well as software faults that are understood to be non-critical. If many of the commercial parts were switched to military-grade parts, the expected mean time to failure would be 2,300 hours. Both calculated mean times to failure for the Amine Swingbed use conservative failure rate models. The observed mean time to failure for CDRA is 2,500 hours. Working on this project and for NASA in general has helped me gain insight into current aeronautics missions, reliability engineering, circuit analysis, and different cultures. Prior my internship, I did not have a lot knowledge about the work being performed at NASA. As a chemical engineer, I had not really considered working for NASA as a career path. By engaging in interactions with civil servants, contractors, and other interns, I have learned a great deal about modern challenges that NASA is addressing. My work has helped me develop a knowledge base in safety and reliability that would be difficult to find elsewhere. Prior to this internship, I had not thought about reliability engineering. Now, I have gained a skillset in performing reliability analyses, and understanding the inner workings of a large mechanical system. I have also gained experience in understanding how electrical systems work while I was analyzing the electrical components of the Amine Swingbed. I did not expect to be exposed to as many different cultures as I have while working at NASA. I am referring to both within NASA and the Houston area. NASA employs individuals with a broad range of backgrounds. It has been great to learn from individuals who have highly diverse experiences and outlooks on the world. In the Houston area, I have come across individuals from different parts of the world. Interacting with such a high number of individuals with significantly different backgrounds has helped me to grow as a person in ways that I did not expect. My time at NASA has opened a window into the field of aeronautics. After earning a bachelor's degree in chemical engineering, I plan to go to graduate school for a PhD in engineering. Prior to coming to NASA, I was not aware of the graduate Pathways program. I intend to apply for the graduate Pathways program as positions are opened up. I would like to pursue future opportunities with NASA, especially as my engineering career progresses.

Dunbar, Tyler↗

NASA NTRS2017

Flight Test Evaluation of an Unmanned Aircraft System Traffic Management (UTM) Concept for Multiple Beyond-Visual-Line-of-Sight (BVLOS) Operations

Many applications of small Unmanned Aircraft System (UAS) have been envisioned. These include surveillance of key assets such as pipelines, rail, or electric wires, deliveries, search and rescue, traffic monitoring, videography, and precision agriculture. These operations are likely to occur in the same airspace in the presence of many static and dynamic constraints such as airports, and high wind areas. Therefore, operations of small UAS need to be managed to ensure safety and operation efficiency is maintained. NASA has advanced a concept for UAS Traffic Management (UTM) and has initiated a research effort to refine that concept and develop operational and system requirements. A UTM research platform is in development and flight test activities to evaluate core functions and key assumptions focusing exclusively on UAS operations in different environments are underway. This seminar will present lessons learned from a recent flight test focused on enabling operations of multiple UAS in lower-risk environments within and beyond visual line of sight (BVLOS).

UTM↗

DOE OSTI2023

Stress characterization for friction-stir-welded electric vehicle battery trays with application of neutron diffraction

The battery tray is an essential component that protects and controls battery-cell temperatures in electric and plug-in hybrid vehicles. The functional stress limit of the battery tray heavily depends on the residual stress acquired from the manufacturing process. Consequently, exceeding the stress limit of the battery tray during operation could compromise the battery-cell banks and may risk the vehicle's safety. Hence, understanding residual stress formation is vital for design and safety concerns. Here, in the current study, AA 6061-plates were friction stir welded to an A365 high-pressure die-cast battery tray to create sealed coolant channels in the battery tray. However, this multi-material lap friction stir weld introduces residual stress into the battery tray, resulting in distortion. This distortion was mitigated using burnishing or coining operations, though straightening the battery tray had initially unknown effects on the residual stress. Therefore, neutron diffraction was utilized to characterize residual stresses after straightening. The results indicate that the friction stir welding (FSW) operation generated residual stresses exceeding the yield strength of the material, consequently deforming the battery tray by ±3 mm from the pre-weld geometry. The burnishing operation reduced the residual stresses below the material's yield strength while restoring the tray to within ±0.75 mm of the pre-weld geometry. Similarly, the coining operation restored the battery tray to within ±0.75 mm of the pre-weld geometry, however, increasing the number of locations where the residual stress exceeds the yield strength of the material.

36 MATERIALS SCIENCE↗

DOE OSTI2024

High Velocity Joining of Multi-material Stacks Containing 3rd Generation Advanced High-Strength Stainless Steel and Aluminum Extrusion and Casting (Abstract)

Advanced lightweight materials, including multi-phase steels, aluminum extrusions and aluminum castings, have increasingly replaced mild steel to meet original equipment manufacturer (OEM) demand for increased fuel economy and crash-safety requirements. Third Generation (Gen 3) AHSS provides a superior combination of strength and ductility for crash energy management components in the vehicle body-in-white (BIW). Aluminum extrusions are widely used for bumper, door rocker panel, cradle and battery frame applications. Aluminum castings are increasingly being used in electric vehicles to provide part consolidation, weight saving and increased driving range. Rocker panels are, for example, an important component of the battery electric vehicle (BEV) body structure. The rocker panel serves several purposes, including structural support, crash resistance, protection for the vehicle's underbody and battery tray, and contributing to the overall aesthetics. In order to reduce weight, rocker panels are usually constructed using outer panels consisting of 3rd generation advanced high strength steels (AHSS) and an inner multicell aluminum extrusion structure for energy absorption which protects the batteries in a crash event. It is well known, however, that these material combinations provide significant challenges for joining and are susceptible to liquid metal embrittlement and loss of strength. The overall goal is to find a solution that addresses these challenges in order to produce multi-material vehicle components with reduced weight and minimal galvanic and recyclability issues. The approach being proposed here is to utilize a novel high velocity (HiVe) riveting and clinching technique recently demonstrated by Pacific Northwest National Laboratory (PNNL) to join (2T/3T) sheets of aluminum alloys and steel. This process will not only address the aforementioned challenges but also help significantly reduce the joining cycle time. This work will also demonstrate use of HiVe assemblies to be retrofitted to existing body-shop robots thus having minimal impact to existing body shop operations.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Transmission Operator Workflows for Real-Time Reliability Studies: A Review of Control Room Practices and Naturalistic Decision Making

This report provides an overview of real-time reliability study tools and their use by power system operators in the control room environment. After introducing some of the nuances of the control room environment and the differences in perspectives between power system engineers and operators, the roles and responsibilities of key entities involved in RTCA workflows are introduced. These are specifically the transmission system operator (TOP) and reliability coordinator (RC), which are required to run tools such as real-time contingency analysis (RTCA) as part of a real-time reliability assessment every 30 minutes, as dictated by a series of standards issued by the North American Electric Reliability Corporation (NERC). The process by which power systems operators operate the grid is discussed in terms of naturalistic decision making (NDM) and the recognition-primed decision-making (RPD) model. This cognitive model describe how experts working in high-risk, high-stress environments make safety-critical decisions under uncertainty and time pressure. For power system operators, the mental simulations involved in the traditional RPD model are supplemented by physics-based simulations using numerical tools, such as RTCA, to improve situational awareness and effectiveness of control actions. Next, a generic workflow is introduced to describe operator decision making for running RTCA tools and responding to system violations on a pre-contingent basis. The types of analysis performed and control actions chosen by power system operators are described in detail. The overall high-level workflow is then expanded in subsequent sections, with special attention given to high-voltage violations, low-voltage violations, and thermal overloads. Each type of violation is described in detail, with explanations of common causes, impacts on equipment and customers, and mitigation strategies. An additional workflow diagram is provided for each type of violation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Pull Force Evaluation of CCS Insulated End Caps

Insulated end caps installed on DC pins of Combined Charging System (CCS) inlets have been identified as potential debris sources within electric vehicle supply equipment (EVSE) connectors, increasing the risk of electric shock and fire hazards. Although standards such as IEC 62196-1:2022 specify mechanical pull-force requirements for these end caps, it remains unclear whether these requirements provide adequate robustness under real-world conditions. To address this concern, the National Charging Experience (ChargeX) Consortium's Hardware Task Force conducted evaluations of insulated end caps used in OEM CCS inlets. This study assesses the performance of insulated end caps used in OEM CCS inlets, specifically those installed on DC pins, using the procedures defined in IEC 62196-1:2022 (Section Sign) 26.7 and SAE J3400, supplemented by additional experimental conditioning. To ensure relevance to real-world conditions, NLR collaborated with charging network operators (CNOs) to guide the selection of charging inlet samples. Material analyses of the insulated end cap samples were conducted to confirm that the tested materials reflected the types and properties commonly observed in the field. The selected samples underwent temperature and humidity conditioning followed by pull-force testing to evaluate the end-cap integrity. Although SAE J3400 inlets were not directly tested due to limited diversity in available field data, the underlying end-cap principles between CCS and SAE J3400 are comparable, allowing the study's insights to be relevant to both technologies. Overall, this study provides a structured evaluation framework to inform potential refinements to mechanical pull-force requirements in charging standards.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Electric Utility Distribution Costs: Scoping Study on Trends, Drivers, and Possible Response Strategies [Slides]

This scoping study synthesizes information that will help stakeholders understand the scope, scale, and drivers of recent increases in investor-owned utility (IOU) expenditures on local distribution power grids, while providing regulators and other decision-makers with potential strategies to keep electricity bills down. The study includes five distinct components. Drawing first on data from FERC Form 1, it summarizes key trends in past and recent IOU distribution costs. Next, through a review of a sample of distribution-system plans, it characterizes material drivers of planned distribution expenditures. Ultimately, regulators must approve cost recovery for IOU expenditures, including those for the distribution system. The study therefore also: examines trends in utility requests and regulatory approvals related to changes in retail rates and return on equity; identifies areas where utility shareholder and customer incentives may be misaligned; and develops a menu of options that state regulators might consider to optimize distribution system expenditures. Some of the key findings include: - IOU distribution spending at a national level has grown by 6%/yr since 2014 in real dollar terms, 4x faster than in the prior 20 years and consisting mostly of capital (not operating) expenditure. - On a per-kWh basis, increases in IOU distribution costs since 2014 represent over 30% of the overall national-average increase in retail electricity rates. - Regional spending growth has ranged from 2-8%/yr, with larger estimated rate impacts in CAISO, then NYISO & ISO-NE, and then the Southeast, MISO & PJM (see figure). - Some utilities are planning for significantly increased distribution system spending. Planned spending on managing the existing system (asset replacement, safety & reliability, and resilience are all important drivers) exceeds that for capacity expansion. - IOU rate increase requests ($18 billion in 2025) and public utility commission (PUC) approval levels (average of 64% of requested amounts from 2021-2025) have recently hit multi-decadal highs. - PUCs in New England and the Southeast have recently approved a greater fraction of rate requests (>75%, on average) than in ther regions, while PUCs in California and the Southeast have generally authorized higher equity returns than in other regions. - Regulators have many tools to tackle potential misalignments between utility and customer interests and, more specifically, to optimize and reduce distribution costs. Shorter-term options include those related to return on equity, capital structure, depreciation, trackers, construction work in progress, and securitization. Longer-term options include performance-based regulation and a wide variety of planning-related requirements. All options embed important tradeoffs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Integrating Resilience Planning in Distribution System Planning

Electric utilities, regulators, and stakeholders face increasing risks of severe storms, freezes, floods, and heat waves damaging grid infrastructure and causing power outages—and increasing risks of utility equipment igniting wildfires. At the same time, customer electricity rates have risen substantially in recent years, due in part to replacing aging infrastructure and improving resilience to natural hazards and physical threats. To address these challenges, utilities are beginning to move beyond traditional, siloed planning processes to balance resilience with other fundamental grid objectives such as affordability, reliability, safety, and serving new loads. This study presents a framework for states and utilities that want to advance integration of resilience and distribution planning processes to improve planning efficiency, better prioritize cost-effective grid expenditures, and balance planning objectives. The framework includes 7 key integration points between these planning processes: -Strategy process -Data -Threat assessments -Solution identification and prioritization -Optimization opportunities -Consideration of other grid needs -Metrics Lawrence Berkeley National Laboratory reviewed utility distribution system plans and interviewed subject matter experts to identify emerging practices for each of the 7 integration points. This report presents these practices, which can be used as a guide toward more holistic planning and cohesive investment strategies. It also includes 3 case studies to provide practical examples of how utilities apply such integrated planning processes: two pole hardening programs and one microgrid planning effort. The report concludes by identifying opportunities for future research.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1995

Liquid-Feed Methanol Fuel Cell With Membrane Electrolyte

Fuel cell generates electricity from direct liquid feed stream of methanol/water solution circulated in contact with anode, plus direct gaseous feed stream of air or oxygen in contact with cathode. Advantages include relative simplicity and elimination of corrosive electrolytic solutions. Offers potential for reductions in size, weight, and complexity, and for increases in safety of fuel-cell systems.

Surampudi, Subbarao↗

NASA NTRS2003

Safety Interlock for Angularly Misdirected Power Tool

A proposed safety system would effect an inhibitory action whenever a power tool was aimed in a direction outside a prescribed range of allowable directions. The power tool could be a welding torch, blowtorch, laser, drill, or gun, for example. The inhibitory action could be turning off the supply of gas or electric power to the tool; in the case of a gun, the inhibitory action could be actuation of a mechanical trigger stop.

Li, Larry C.↗

NASA NTRSDate not supplied

Flying Qualities Analysis and Piloted Simulation Testing of a Lift+Cruise Vehicle with Propulsion Failures in Hover and Low-Speed Conditions

The recent emergence of electric-Vertical Take-Off and Landing (eVTOL) vehicles for Urban Air Mobility (UAM) applications has resulted in a wide variety of configurations with unique stability and control characteristics. NASA is currently conducting research to develop conceptual design tools to accelerate public acceptance of these vehicles which includes requirements for safety during failure scenarios. This paper summarizes progress toward a toolbox for predicting flying qualities of eVTOL vehicles during critical propulsion failures that could impact the allowable design of the vehicle geometry or control system. Key topics include unique vulnerabilities of eVTOL/multirotor vehicles to propulsion failures, relevant flying qualities design metrics, and simulation modeling requirements for assessing flying qualities degradation due to failures. Results of a piloted simulation study conducted in the NASA Ames Vertical Motion Simulator (VMS) are presented. The VMS experiment was designed to assess and validate key handling qualities and safety design metrics for propulsion failures. These results show the correlation between control system design requirements and the degradation in handling qualities for various propulsion failures.

George Altamirano↗

DOE OSTI2024

Concept Study of Robotic Camera-Based Foreign Object Detection for EV Wireless Charging

Wireless charging of an electric vehicle (EV) is an emerging charging technology promising convenient, autonomous, and highly efficient EV charging without requiring heavy gauge cables. However, due to the strong electromagnetic field created by this process that surrounds the wireless charger, the presence of foreign objects can detrimentally interact with it, thus affecting wireless power transfer (WPT) performance or leading to harmful and unwanted safety risks. This paper presents the results for a concept study on a robotic camera-based foreign object detection (FOD) system, as a supplement to the industry-existing overlapped FOD coil array method, for EV wireless charging. A Raspberry PI 4 control board and compatible Raspberry PI Camera Module 2 are used to implement camera-based object detection. The FOD program was developed using a state-of-the-art deep learning object detection model with the OpenCV and Pytorch library and is compatible with camera module hardware. A dry-run test with Raspberry PI and a camera module was conducted and the preliminary FOD function was verified. The feasibility assessment is also validated by comparing the performance of five existing state-of-the-art deep learning object detection models for vehicles, animals, persons, and metals subsets, respectively. Satisfactory performance on the benchmark datasets is observed by the tests, but further improvements are needed in future work when detecting small-sized metallic objects. A programable robotic car is also under development as ongoing work for carrying the Raspberry PI and camera module while moving for the maintenance process.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Safety-Related Instrumentation and Control Pilot Upgrade (Initial Scoping Phase Implementation Report)

This research report (1) describes the process followed and products developed during the SR I&C Pilot Project Initial Scoping Phase, and (2) captures lessons learned. Exelon Generation and LWRS collaborated to develop a Digital Transformation Strategy as part of a larger Advanced Concept of Operations. The proposed SR I&C Pilot Upgrade provides a foundation stone for this Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant Total Cost of Ownership (TCO). Initial Scoping Phase activities for this Pilot Project have been performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process (SDP), NISP-EN-04, Standard Digital Engineering Process (SDEP), and Electric Power Research Institute (EPRI) Report 3002011816, Digital Engineering Guide (DEG). Completing Initial Scoping Phase Engineering and Operations, Licensing, and Project Management Activities was necessary to sufficiently bound the scope, schedule, and estimated cost of the Project to enable utility management to authorize moving into the Conceptual Design Phase. A significant finding of the Business Case Analysis (BCA) methodology developed and applied as part of this effort was that the growth rate of material costs for sustaining the operation of obsolete SR I&C equipment is accelerating. This directly contributed to the Project Economic Analysis created to justify continuing the Project. Project Initial Scoping Phase lessons learned have also been captured to assist the larger industry in understanding the Digital Transformation Strategy and SR I&C Pilot Project Initial Scoping Phase efforts. This is in keeping with the public/private partnership that has been established between the Department of Energy (DOE) and Exelon for this effort with engagement from the NRC. By addressing first-of-a-kind (FOAK) risks and capturing lessons learned, the SR I&C Pilot Upgrade Project addresses technical, regulatory, and business risks to enable subsequent implementers of similar upgrade.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Ribbons Affect Movement of Cracked Solar Cells [Poster]

Cracking of crystalline silicon photovoltaic cells remains a challenging topic in accurately assessing the long-term reliability and performance of affected modules. Cells can be damaged in every stage throughout the lifetime of a photovoltaic module, ranging from manufacturing, transportation, and installation to operation. Initially, the metallization can be able to bridge the gap of fractured cells and keep individual cell fragments electrically connected. However, photovoltaic modules and cells experience thermo-mechanical stresses during operation from temperature changes and pressure cycles of wind and snow loads. This causes the cell fragments to move, which, in turn, can lead to the wear out of the metallization and, consequently, to power loss or a safety hazard. The rate at which this degradation mechanism proceeds is currently unknown. Hence, in this work, we quantify the cell fragment movement of polycrystalline and monocrystalline mini-modules. By using digital image correlation, we were able to extract the normal crack opening and tangential sliding distances of adjacent cell fragments during heating of the mini-modules. Those distances are essential to develop wear-out models for the metallization and determine the rate of the degradation mechanism. We found that the interconnect technology has a significant impact on the direction and quantity of the cell fragment movements.

14 SOLAR ENERGY↗

DOE OSTI2024

Artificial Intelligence/Machine Learning Technology in Power System Applications

The primary purpose of this report is to provide an overview of the advancement in artificial intelligence and machine learning (AI/ML) technologies and their applications in power systems. It offers a foundation for understanding the transformative role of AI/ML in power systems and aims to stimulate further research and development in this area. This report begins with a historical perspective of AI/ML technologies, then explores their advancement to today’s prominence. The document highlights key contributors to the success of AI/ML technologies, including increased computational power, greater data availability, innovative algorithms, and advanced tools. It further introduces various AI/ML techniques, including supervised, unsupervised and reinforcement learning, graph neural networks, and generative AI. It also emphasizes the critical importance of ensuring the safety, security, and trustworthiness of these AI/ML techniques within this sector. The report reviews the recent representative advancements in various power system applications enhanced by AI/ML techniques, underscoring key developments and their transformative impact as evidenced by numerous studies. It also explores both the opportunities and challenges associated with the application of AI/ML technologies to improve power system applications. While the report extensively covers AI/ML applications in power systems, focusing primarily on the technical and operational aspects, it may not thoroughly explore the sociopolitical, economic, and broader regulatory implications of AI/ML integration in power systems. AI/ML techniques hold significant potential for enhancing power system applications; however, they are not omnipotent. It is crucial to acknowledge their limitations and understand that they may not be able to address all challenges in the power system domain. Various factors must be considered that influence the implementation, adoption, and effectiveness of AI/ML solutions, including but not limited to safety, security, transparency, and trustworthiness. Additionally, the incorporation of advanced human–machine interfaces is essential, as it enables humans to validate the effectiveness of AI/ML solutions while remaining actively engaged, fostering trust in AI/ML deployment. Finally, the report summarizes AI/ML research activities supported by the Department of Energy (DOE) Office of Electricity (OE) through the Advanced Grid Modeling (AGM) program. The work aligns with the interests and mission of DOE-OE AGM, with the report serving as a resource for identifying existing progress and for pinpointing future applications within AI/ML that need further exploration and support.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler

The growth of renewable energy sources presents a pressing challenge to the operation and maintenance of existing fossil fuel power plants, given that fossil fuel remains the predominant fuel source, responsible for over 60% of electricity generation in the United States. One of the main concerns within these fossil fuel power plants is the unpredictable failure of boiler tubes, resulting in emergency maintenance with significant economic and societal consequences. A reliable high-temperature sensor is necessary for in situ monitoring of boiler tubes and the safety of fossil fuel power plants. In this study, a comprehensive four-stage multi-physics computational framework is developed to assist the design, optimization installation, and operation of the high-temperature stainless-steel and quartz coaxial cable sensor (SSQ-CCS) for coal-fired boiler applications. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. With the simulation-guided sensor installation plan, the newly designed SSQ-CCSs have been employed for field testing for more than 430 days. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

42 ENGINEERING↗