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At least 1,027 records · Page 57

A comparative assessment of the economic viability of nuclear-integrated direct air capture systems

Direct air capture (DAC) systems require heat and electricity to operate, which can be supplied by nuclear power plants (NPPs). In this study, the performance and cost of various conceptual nuclear-DAC systems are assessed, and their performance is compared with several non-nuclear options. Three nuclear-DAC systems are considered: (1) a liquid solvent direct air capture (L-DAC) system with heat supplied from natural gas (NG) and electricity supplied by an NPP, (2) an electrified L-DAC system, fully powered by electricity from an NPP, and (3) a solid sorbent direct air capture (S-DAC) system utilizing both heat and electricity generated by an NPP. Two nuclear technologies are considered: a pressurized water reactor and a high-temperature gas-cooled reactor. Under the medium conservatism scenario, the levelized cost of direct air capture (LCOD) for these systems range from $\$$310/tCO 2 to $\$$525/tCO 2 with the L-DAC system having an NG heat supply at the lower end of the range, and the electrified L-DAC system and the S-DAC system at the higher end of the range. Coupling with nuclear energy led to a 21 % reduction in LCOD for the L-DAC system with NG heat supply and a 29 % reduction for the S-DAC system when compared to fully NG-powered options. When powering the DAC system with grid electricity, the LCOD is highly dependent on the assumed electricity price and carbon intensity. The nuclear option is the cheaper choice when the price of low-carbon grid electricity exceeds $\$$95/MWh and $\$$45/MWh for the L-DAC and S-DAC systems, respectively.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Data-Driven Modeling of High-Resolution Residential Load Profiles Using Low-Resolution Smart Meter Measurements

Accurate and high-resolution residential load profiles are essential for power system modeling, demand response planning, and effective grid operation. As the energy sector moves towards a more actively managed distribution system, the ability to understand residential energy consumption at a minute-by-minute scale becomes increasingly critical. High-resolution load profiles provide key insights into demand patterns and user behavior, enabling grid operators to design more effective energy solutions; however, residential load measurements in the field are typically recorded at low resolutions, such as 15-60 minutes, which makes it hard to study the characteristics of different residential customers. This paper addresses these challenges by introducing a data-driven approach to generate realistic, high-resolution residential load profiles based on lowre-solution measurements and weather information. The proposed method retains the key features of the actual residential load measurements while offering appliance-level energy consumption details for each residential building. The results demonstrate the effectiveness of the proposed load profile generator, proving its capability to support utilities in optimizing residential energy management and ensuring a more reliable and resilient grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Exploring sustainable electricity system development pathways in South America’s MERCOSUR sub-region

South America has abundant natural water and energy resources, and exploiting these resources to achieve a clean energy future is central to the continent’s economic and sustainable development objectives for the next several decades. Designing pathways to achieving this clean energy future requires better understanding the structural, techno-economic, and policy forces that may influence the future development of the electricity sector in the region. Here, we focus on an interconnected electricity system of five South American countries – Argentina, Brazil, Chile, Paraguay, and Uruguay – which represent major electricity generation, consumption, and trade dynamics in the region. We explore the implications of various forces that could shape the future composition of the power sector in the sub-region, including: evolving renewable energy cost and performance, natural gas prices, cross-border interconnection facilities, early retirement of installed hydropower, and different decarbonization goals. We use a model framework based on a power system planning platform (GridPath) to co-optimize investment and operations of generation, storage, and transmission facilities out to 2050. Our results in a Reference scenario indicate that the electricity system can maintain a relatively clean energy portfolio by leveraging existing hydropower capacity and integrating increasingly cost-competitive wind and solar power. However, dependence on natural gas in the region is likely to remain high. A low-carbon electricity system can cost-effectively be achieved through policy interventions (e.g., renewable portfolio standards) and by diversifying investments in wind, solar, battery storage, and some new hydropower capacity. We also find that existing hydropower is critical for maintaining reliable future grid operations. Enhanced regional electricity trade, mostly based on existing interconnection capacities with nominal investment in new transmission, can significantly benefit the clean energy transition in the region.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Effects on Structure’s Electromagnetic Shielding Effectiveness Considering Penetrating Cables Coupling Energy from HEMP Event

The threat of weaponized electromagnetic pulse (EMP) is a serious factor in defining power system resilience. Without adequate knowledge regarding the interaction between EMP and power system infrastructure, system personnel may be unable to plan for and operate during an EMP event and major blackouts could occur. This work studies the interaction between EMP and structures, specifically analyzing the shielding effectiveness of buildings emulating power generation facilities. The main focus is to determine how penetrating cables affect the structure’s shielding effectiveness. Several cable parameters including height above ground, radius, termination configuration, and length are analyzed via computational electromagnetic simulations. Results demonstrated penetrating cables can significantly diminish a structure’s shielding effectiveness, especially the electric field. Length of cable is the most influential parameter.

Mignardot, David↗

Infrastructure and DFLAW Support at Hanford - 20443

Manhattan Project era infrastructure systems are degrading at an accelerated pace across the Department of Energy's (DOE) Environmental Management complex. Revitalizing, rejuvenating and right-sizing these systems to ensure reliability for ongoing cleanup missions is a major focus at the 580-square- mile Hanford Site in southeast Washington State. The push to complete construction, commissioning, startup, and operation of facilities and systems in the Direct-Feed Low-Activity Waste (DFLAW) program at Hanford by 2023 requires considerable coordination among site contractors and a significant investment in infrastructure. The passage of time also poses a challenge. It has been about 75 years since facilities were first operated at the site, and approximately 40 years of plutonium production created a legacy of unidentified active and abandoned underground obstacles and waste sites that must be avoided when building and upgrading the infrastructure. Converting infrastructure systems originally built to support plutonium production from the 1940's to the 1980's and upgrading those systems to optimize technology is an ever-changing balance of funding profiles, available resources and execution strategies. The DOE Richland Operations Office (RL) has long recognized the need for increased investment in Hanford Site infrastructure to support the future processing of approximately 56 million gallons of waste currently stored in large underground tanks. When DFLAW is fully operational, safe and reliable infrastructure systems will be needed to ensure continuity of operations around the clock, 365 days a year. These include roadways, water, power, sewer, information technology systems and facilities. To ensure the readiness of Hanford's infrastructure to support treating tank waste in the next three years, 15 projects were identified with a combined value of $133.8 million. Through calendar year 2019, 7 infrastructure projects have been substantially completed and the remaining 8 projects, with a remaining value of $103.8 million, are scheduled to be completed by December 2023. RL and its site services/infrastructure contractor, Mission Support Alliance (MSA), regularly evaluate the needs of the DFLAW program and other Hanford Site missions to ensure the highest priority systems are addressed. In addition to a fast-approaching deadline for round-the-clock treatment operations, RL and MSA face another significant infrastructure challenge. As cleanup is being completed in a 220-square-mile area called the River Corridor, most of the cleanup operations going forward will occur in a 20-square-mile area in the center of the Hanford Site, known as the Central Plateau. Infrastructure systems are becoming more congested in an already overcrowded area. This paper/presentation will outline some of the challenges Hanford faces while executing infrastructure reliability projects. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NRC Reactor Operating Experience Analysis and Trend Summary: 2024 Update

This report presents a summary of the Nuclear Regulatory Commission’s (NRC’s) reactor operating experience analyses with data through 2024 as well as the reliability and frequency trends identified in the 2024 update reports for the component performance studies, loss-of-offsite power analysis, initiating events analysis, and system studies provided on the NRC Reactor Operating Experience Results and Databases website (https://nrcoe.inl.gov/).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DeepGraphONet: A Deep Graph Operator Network to Learn and Zero-Shot Transfer the Dynamic Response of Networked Systems

This article develops a deep graph operator network (DeepGraphONet) framework that learns to approximate the dynamics of a complex system (e.g., the power grid or traffic) with an underlying subgraph structure. Here, we build our DeepGraphONet by fusing the ability of graph neural networks to exploit spatially correlated graph information and deep operator networks to approximate the solution operator of dynamical systems. The resulting DeepGraphONet can then predict the dynamics within a given short/medium-term time horizon by observing a finite history of the graph state information. Furthermore, we design our DeepGraphONet to be resolution independent. That is, we do not require the finite history to be collected at the exact/same resolution. In addition, to disseminate the results from a trained DeepGraphONet, we design a zero-shot learning strategy that enables using it on a different subgraph. Finally, empirical results on the transient stability prediction problem of power grids and traffic flow forecasting problem of a vehicular system illustrate the effectiveness of the proposed DeepGraphONet.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Resilient Operation of Networked Community Microgrids with High Solar Penetration

This project, funded by the US Department of Energy’s Solar Energy Technologies Office (SETO), focused on the operation of microgrids as a coordinated network. The primary objective, which was successfully achieved, was to develop both control strategies and hardware solutions to support the resilient and efficient operation of networked microgrids with high solar penetration. The work was structured around the following four main tasks: • Development of distributed and scalable optimization algorithms for AC-coupled networked microgrids. • Design and implementation of a novel DC interconnection hardware to enable precise power exchange between microgrids. • Laboratory operational validation of the developed technologies using 480 V testbeds and commercially available hardware. • Field operational validation of the complete solution in Adjuntas, Puerto Rico, interconnecting two kW-scale, split-phase microgrids of Casa Pueblo’s microgrids. This project addressed multiple technical challenges across the domains of optimization, control, hardware interconnection, and protection. One of its key contributions was delivering tangible, real-world solutions for networking microgrids. In contrast to purely theoretical or simulation-based work, this project included full-scale hardware operational validation both in the lab and in the field. The work conducted as part of this project—in collaboration with the University of Puerto Rico; the University of Tennessee, Knoxville; the University of Central Florida; and Casa Pueblo—has advanced the state of the art in networked microgrids. Key contributions include the development of distributed control strategies, practical solutions for real-world implementation challenges, and the introduction of a novel DC interlink approach for microgrid interconnection. The project featured both laboratory and field validation using commercial off-the-shelf components. The field deployment successfully validated that a group of microgrids can operate in a coordinated manner, enabling precise power flow between systems and mutual support during extreme events. This project resulted in 15 journal publications and 15 conference papers; 5 graduate students and 15 undergraduate students were supported. The codes of distributed optimization and forecasting were made open-source through OSTI.gov for distributed optimization and forecasting. All the publications are available in the ORNL-hosted project landing page. The DC interlink with state-of-charge balancing control was operationally validated in Adjuntas by interconnecting two real-world, 240 V split-phase microgrids. To the best knowledge of the team, this represents the first operational validation of AC microgrids interconnected via DC-interlinks. As a culmination of this project, a follow-on grant was awarded to support the technology transfer of the distributed optimization framework to a commercial microgrid controller, Stellar Edge, developed by the California-based company New Sun Road.

14 SOLAR ENERGY↗

Large-Scale Adoption of Self Synchronized Universal Droop Controller-Based Inverters to Enable Ancillary Services for Different Modes of Distribution System Operations

This poster presents the results of using the self-synchronized universal droop controller to enable solar power to provide ancillary services so that the use of solar power can be increased. A 300-node system using the IEEE 123 bus test feeder are modeled on a real time power system simulator with the results presented.

Arce, Laura↗

Theoretical Analysis of a Single-Stage Gas-fired Ejector Heat Pump Water Heater

Ejector-driven systems have the ability to operate at high efficiencies, utilizing recycled thermal energy as a power source. For a typical ejector heat pump (EHP) system, the increase of the condenser temperature reduces the coefficient of performance (COP). In addition, if the condenser temperature is higher than the critical temperature, the ejector may not function. In this situation, the condenser temperature must be reduced, and an additional heater will be utilized to heat the production water from the condenser temperature to the desired temperature. In this study, a single-stage gas-fired EHP is investigated and thermodynamically modeled to optimize the system COP for the purpose of heating water by utilizing the thermal energy from the ambient air. The effects of the high-temperature evaporator (HTE) and low-temperature evaporator (LTE) on the ejector critical back pressure and the EHP system performance are examined for a HTE temperature range of 120–180 °C and LTE temperatures of 15.5, 17.5, and 19.5 °C. Our results show that an optimized COP for the EHP system exists and is dependent on HTE and LTE temperatures and the primary nozzle throat diameter. In addition, it is found that the peak EHP COP does not necessarily coincide with a large ejector COP. From this study, a maximum EHP COP of 1.31 is achieved at a HTE temperature of 170 °C and LTE temperature of 19.5 °C with a total heating capacity of 15.98 kW.

42 ENGINEERING↗

A Relaxed PV Bus Model in Linear Power Flow

The emerging multimodal active energy resource units make it necessary to introduce constant voltage amplitude buses (PV bus) in the operation of modern distribution systems. To enable the analysis of PV bus using linear power flow models, this letter proposes a relaxed PV bus model for solving power flow related problems using an indirect modeling approach. The developed PV bus model can be applied to linear power flow models in both rectangular and polar coordinates. Besides, the approximation error of the relaxed PV bus model can also be controlled and quantified. Lastly, the proposed relaxed PV bus model is validated using different test systems. According to the numerical studies, the maximum error on the PV bus approximation in all case studies is only 0.61%, and the maximum error of the supporting power at the PV buses is 6.5%.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Forecasting Solar-Thermal Systems Performance under Transient Operation Using a Data-Driven Machine Learning Approach Based on the Deep Operator Network Architecture

Modeling and prediction of the dynamic behavior of thermal systems operating under intermittent energy input and variable load requirements represent one of the greatest challenges in the development of efficient and reliable renewable-based power generation technologies. In this work, a data-driven machine learning modeling framework was developed based on a modified version of the Deep Operator Network architecture where the time coordinate in the trunk net is replaced with historical data of the predicting quantity. The modeling framework can be used to accurately predict the performance of renewable-based energy conversion technologies including wind- and solar-based power plants. This novel framework was applied on a solar-thermal system that consists of a solar collection loop using a flat plate collector, a power generation loop comprising an Organic Rankine Cycle, and a thermal energy storage tank connecting both loops. Variable solar irradiance, air temperature, and power load profiles were used by the Deep Operator Network to predict the State-of-Charge and the efficiency of the thermal system for several days. The results were compared with the State-of-Charge and efficiency functions calculated using a physics-based model. For a simple operation scenario, characterized by a clear sky solar irradiance profile and constant load, the standard deviation in the State-of-Charge prediction by Deep Operator Network is below 0.9% during a seven-day prediction time horizon. For the most realistic operation scenario that considers real solar irradiance and a rough load profile, the maximum standard deviation in the predictions for the State-of-Charge and efficiency are below 6.8% and 2.5%, respectively. A comparison between Deep Operator Network and Long Short Term Memory network was also performed. In general, both networks predict very well the State-of-Charge for different data density conditions; however, a higher accuracy, with a standard deviation below 2.0%, is obtained by the Deep Operator Network during three and half days using sparser training data of 20-minute points. The same accuracy for the State-of-Charge prediction with the Long Short Term Memory network is achieved only for 14 h. Average standard deviations for the State-of-Charge prediction of 1.1% with the Deep Operator Network and 1.5% with the Long Short Term Memory network are obtained for a four-day prediction time using a denser training data of 5-minute points.

DeepONet↗

Informing Plant Asset Reliability and Availability Through AI-Driven Analysis of Operator Logs

The availability and reliability of nuclear power plant (NPP) structures, systems, and components (SSCs) are critical parameters for NPP safety. Tracking these parameters is necessary but costly and labor-intensive, requiring the collection and evaluation of SSC event data such as shutdowns, startups, and failures. To show how these events are needed for the parameters an example is given: one measure of reliability is based on the number of equipment failure events and the number of run hours (i.e., the time from a startup event to a shutdown event). Here, this work investigates using artificial intelligence (AI) to mine NPP operator log entry texts for SSC event data. Four AI approaches were explored for identifying these events, including natural language processing (NLP) methods, generative AI, generative AI combined with NLP, and topic modeling. A key challenge addressed with all four approaches is the brevity of operator log entries. Among these four a neural network–based NLP method was shown to be the most promising for this application, achieving F1 scores of 86.0% for shutdowns, 92.2% for startups, and 80.4% for failures on a subject-matter-expert-curated dataset from NPP operator logs, compared to a baseline of 66.6% for a random classifier. This shows that NLP methods can perform better than generative AI. Additionally, the NLP methods combined with generative AI were shown to perform better than generative AI alone. Generative AI was most successful at providing the background information for the NLP methods to use. This work demonstrates the potential to use AI to automate parameter collection from NPP operator log entries and other records.

97 - MATHEMATICS AND COMPUTING↗

Demonstration of a modeling toolkit for the design of building electrical distribution systems

The deployment of building equipment (e.g., lighting, security) and miscellaneous electrical loads that fundamentally require DC power for operation is increasing. Powering these DC loads has traditionally required an AC/DC converter, but the installation of photovoltaic (PV) and battery energy storage systems that primarily produce DC power eliminates the need for AC/DC converters at each end-device. However, analyzing system energy efficiency and cost for different electrical distribution architectures can be challenging as software tools that support this are not readily available. This paper presents preliminary results from a laboratory verification of the Building Electrical Efficiency Analysis Model (BEEAM) toolkit that was developed to address this gap. Three different eight-luminaire lighting systems comprised of market-available products were designed and modeled: one that used traditional AC distribution, a second that used a hybrid AC -to- centralized DC electrical distribution architecture, and a third that used a hybrid AC -to- distributed DC architecture. Notably, AC/DC conversions are required in all three systems. BEEAM models for LED drivers as well as Power-over-Ethernet (PoE) switches were created using laboratory characterization data. The lighting systems were simulated in Modelica, and the results were compared with each other and physics-based expectations. Simulation results show that PoE system energy efficiency is highly dependent on both device specification (e.g., LED driver and PoE switch efficiency) and system architecture (e.g., PoE switch loading) choices, as expected. For the products and system architectures selected for this study, the two DC systems were found to be less efficient than the AC system over the course of typical operation. In future work, simulation results will be compared with laboratory measurements to validate the usefulness of this software for design, and lighting systems with integrated PV and battery energy storage will be simulated to quantify the energy performance improvements that result from the elimination of some AC/DC converters.

Waghale, Anay S.↗

Optimizing Insulation Design for Transformers in Medium Voltage Power Conversion Systems

Medium-frequency transformers (MFTs) play a crucial role in medium-voltage (MV) solidstate transformer (SST) systems, particularly in extreme fast charging applications. Achieving partial discharge (PD)-free operation while maintaining high power density is a significant challenge due to the high electric field (E-field) stresses inherent in MV applications. This dissertation focuses on the insulation design and optimization of MFTs used in both the main power electronics circuits and auxiliary power supplies. The study begins with an overview of insulation testing methodologies, including high potential tests, basic insulation level tests, and PD tests, which are critical for evaluating MFT insulation reliability. Given the importance of PD-free operation for long-term reliability, particular emphasis is placed on understanding PD mechanisms, including void, corona, and surface discharge, and their mitigation strategies. A high voltage isolated auxiliary power supply is then introduced, utilizing a gapped transformer encapsulated in silicone gel. This design achieves PD-free insulation up to 18 kV RMS while maintaining low coupling capacitance to minimize common-mode current. The proposed solution ensures reliable operation in MV environments and offers a scalable approach for auxiliary power in cascaded SST architectures. To improve MFT insulation in main power conversion circuits, a novel structure is developed using polypropylene sheets and potting compounds to create a void-free air gap, effectively mitigating E-field intensity. A prototype transformer with this insulation structure is built and achieves PD-free operation up to 30 kV RMS. This design is experimentally validated in a resonant converter operating at 46 kW, demonstrating its feasibility for MV SST applications. Further optimization is implemented to enhance MFT performance for dual-active-bridge(DAB) converters by integrating a semiconductive shielding layer within the insulation structure. This shielding layer improves the magnetic coupling coefficient while effectively confining the E-field within high insulation materials, thereby reducing eddy current losses. The optimized MFT achieves PD-free operation at 12.6 kV RMS and is successfully tested in a DAB converter operating at 43 kW, which meets the insulation requirements for a 13.2 kV SST system. This dissertation advances MFT insulation design by introducing and experimentally validating novel approaches that improve high voltage insulation while optimizing magnetic coupling and manufacturability. The proposed insulation structures enable PD-free operation while minimizing insulation material usage and simplifying assembly, making them ideal for high power, high voltage applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Real-time Simulation of Coordinated Sub-Transmission Volt-Var Control Tool under High Distributed PV Penetration

With the rapid penetration of intermittent solar photovoltaic (PV) and other distributed energy resources (DER) into the grid, and subsequent changes in power flow patterns in both distribution and sub-transmission, voltage regulation is becoming a major challenge. It is prudent to leverage PV and DER to provide ancillary services to the grid, such as voltage regulation. Recently, a quasi-static, coordinated real-time sub transmission volt-var control algorithm (CReST-VCT) was developed for voltage regulation under high PV penetration by dispatching the reactive power settings of the shunt devices and PV inverters. The algorithm was validated offline, on a quasistatic study. Such quasi-static dispatching algorithms cannot guarantee its performance for highly nonlinear dynamical power systems. In this paper the performance of the algorithm is validated with a real time nonlinear dynamic simulation of a modified IEEE 118 bus system in Opal-RT. The real time simulation is used to emulate the actual system operation, providing a more realistic testing environment for CReST-VCT. The dispatch and control signals are communicated between the power system (Opal solver) and the control center (GAMS solver) in real-time with a MODBUS bridge. The results demonstrate i) system is stable with the new dispatch points ii) significant improvement in system-wide voltage profiles compared to an uncontrolled scenario. Another significant contribution of the work is developing a framework for dispatchable, long duration dynamic simulations that can be leveraged for market/dispatch studies.

CReST-VCT, Opal-RT, Volt/Var Control, renewable in↗

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↗

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↗