Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “load data”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,135 records · Page 63

A Predictive Prescription Framework for Stochastic Unit Commitment Using Boosting Ensemble Learning Algorithms

To take unit commitment (UC) decisions under uncertain load, most existing stochastic optimization (SO) frameworks adopt a generic representation of uncertainty. While load levels that materialize on a particular day are influenced by various covariates (such as the day of the week or temperature), SO frameworks typically disregard such side observations, wasting actionable information that could significantly enhance decision quality. Here, this article proposes a contextual SO (CSO) framework for UC under uncertain load, which can effectively exploit covariate observations in conjunction with a class of machine learning (ML) algorithms to improve the out-of-sample performance of UC decisions. It shows how three ML algorithms, adaptive boosting, gradient boosted trees, and extreme gradient boosting, can be used to this end, constituting the first application of these algorithms in any CSO framework. Using real-world data harvested from the New York ISO grid, we measure the out-of-sample performance of the framework in terms of total operation cost, shed load values, locational marginal prices, and total payments by the loads, against several benchmark methods proposed in the literature. The article has an online companion (Yurdakul et al.), wherein we present additional results and lay out further mathematical formulations used in this work.

42 ENGINEERING↗

A data-driven linear formulation of the optimal demand response scheduling problem for an industrial air separation unit

Demand response (DR) has become a key element in balancing the power grid as the contribution of time-varying renewable power generation increases. Chemical plants are appealing candidates for DR programs as they offer large, concentrated and flexible loads. DR participation calls for frequent production rate changes over time scales that overlap with the dominant dynamics of the plant. Production scheduling should therefore consider the process dynamics explicitly. Here we present a data-driven approach for modelling the scheduling-relevant dynamics based on historical closed-loop operating data using autoregressive with extra inputs (ARX) models. We introduce a new, linear scheduling problem formulation based on the ARX representation, and demonstrate its implementation on an industrial air separation unit.

42 ENGINEERING↗

Calculation of the Vertical Strata Load of Utility Tunnel Crossing Ground Fissure Zone

A ground fissure is a geological disaster in which the vertical dislocation of strata causes surface rupture. Ground fissures can cause extreme harm to the surface and underground buildings. Ground fissure activity can result in different settlement on the two sides of the strata, which will generate additional stress (pressure) that differs from the stress of the general stratum on underground structures across the ground fissure zone. It is essential to assess the effective stress of strata in the design of underground engineering structures across a ground fissure zone. The Xi’an ground fissure through a utility tunnel was focus of the research, and a physical model and data for oblique crossing of the 45° ground fissure were analyzed. A model of the utility tunnel structure was established, including the surrounding soil load as an active ground fissure environment. This model was used to calculate the vertical formation pressure of the overlying soil on the utility tunnel. A method to calculate the overlying load on the utility tunnel caused by ground fissure activity was proposed and compared with the calculation based on the A. Marston principle. The results showed that the ground fissure load calculation method based on the strata-holding effect can effectively calculate the earth pressure of the surrounding soil layer of the utility tunnel in the cross-ground fissure section. The results of this work provide guidance and reference value for the design of a utility tunnel in an area with the potential for a ground fissure.

Zhang, Dan↗

A Two-Level Model Predictive Control-Based Approach for Building Energy Management including Photovoltaics, Energy Storage, Solar Forecasting and Building Loads

This paper uses a two-level model predictive control-based approach for the coordinated control and energy management of an integrated system that includes photovoltaic (PV) generation, energy storage, and building loads. Novel features of the proposed local controller include (1) the ability to simultaneously manage building loads and energy storage to achieve different operational objectives such as energy efficiency, economic cost efficiency, demand response and grid optimization through the design of specific power trajectory tracking performance functionals, (2) an energy trim function that minimizes the impact of solar forecasting errors on system performance, and (3) the design of a state of charge controller that uses day-ahead forecast of solar power and building loads to intialize energy storage at the start of each day. The local controller is tested in simulation using an exemplary system with PV generation, energy storage and dispatchable building loads. Two sample days with different PV forecasts and multiple case scenarios are considered, and the performance of the algorithm in managing the real and reactive net building load trajectories and the ramp rate of PV injections into the utility network are evaluated. The simulations are based on actual forecasted and measured PV data, and the results show that the local controller meets the tracking requirements for real and reactive power within the operating constraints of the building.

14 SOLAR ENERGY↗

Analyzing the Impact of Future Weather Data on Energy Consumption in Weatherization Assistant

This study supports the mission of the U.S. Department of Energy’s Weatherization Assistance Program (WAP), which aims to increase the energy efficiency of dwellings and reduce their total residential expenditures. Specifically, we examine how projected future climate conditions may affect residential building energy performance by integrating future weather data into the National Energy Audit Tool (NEAT). Since WAP evaluates the cost-effectiveness of retrofit measures over lifespans of up to 30 years, accounting for evolving climate conditions is increasingly important. To reflect future household energy demands, this study replaces historically based Typical Meteorological Year (TMY3) weather inputs with Future Typical Meteorological Year (fTMY) datasets derived from global climate model (GCM) projections. A simulation-based framework was established to enable NEAT analysis under future weather conditions. This workflow involves converting EPW-format weather files into JSON inputs compatible with NEAT and generating degree-hour metrics needed for load calculations. The fTMY dataset used in this study was developed by Oak Ridge National Laboratory through downscaling of six GCMs under different emission scenarios and covers the period from 2020 to 2100. In contrast, the TMY3 dataset is based on historical weather data from 1961 to 1990. Simulations were conducted for benchmark single-family prototype buildings across ASHRAE climate zones 1–7, which cover all regions of the U.S. except the subarctic Zone 8 in northern Alaska, evaluating both heating and cooling loads under TMY3 and fTMY conditions. Four foundation types were tested, while heating systems were standardized, as NEAT does not differentiate thermal energy load by HVAC system type in its load calculations. Results show that fTMY weather input consistently yield lower heating loads and higher cooling loads across most locations, aligning with expected climate warming trends. Notably, colder regions such as zones 6A, 6B, and 7 experience marked reductions in heating load, while warmer and transitional zones, such as 2A (Lufkin, TX) and 3C (San Francisco, CA), have substantial increases in cooling loads. Although this study does not directly assess the performance of retrofit measures under future climate conditions, it provides a critical foundation for doing so. By quantifying shifts in baseline (i.e., pre-retrofit case) energy loads between historical and future weather files, the study highlights the importance of integrating climate-responsive data into audit tools. These findings will inform future efforts to evaluate the long-term effectiveness and cost-effectiveness of weatherization measures under changing climate conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Validation of FAST.Farm Against Full-Scale Turbine SCADA Data for a Small Wind Farm

FAST.Farm is a new midfidelity engineering tool developed by the National Renewable Energy Laboratory targeted at accurately and efficiently predicting wind turbine power production and structural loading in wind farm settings, including wake interactions between turbines. FAST.Farm is based on some of the principles of the Dynamic Wake Meandering model—including passive tracer modeling of wake meandering—but addresses many of the limitations of previous Dynamic Wake Meandering (DWM) implementations. Previous FAST.Farm verification studies show the similarities and differences between FAST.Farm and large-eddy simulations for rigid and flexible turbines. In this validation study, FAST.Farm turbine responses are compared to multiturbine measurements from a subset of a full-scale wind farm. FAST.Farm predictions of turbine generator power, rotor speed, and blade pitch for five-turbine simulations are compared to supervisory control and data acquisition results. Results reveal that FAST.Farm generator power mean and standard deviation results reasonably match measured data for upstream and downstream turbines, as well as the mean rotor speed and blade pitch above rated wind speeds. However, FAST.Farm generally underpredicts the mean rotor speed and overpredicts the mean blade pitch below rated operation. These errors are likely related to inaccuracies in the generic controller simulated. Despite controller differences, FAST.Farm predicts the same overall relative rotor power trends for all waked turbines at all wind speeds.

17 WIND ENERGY↗

Key results from examinations of seven high burnup pressurized water reactor spent nuclear fuel rods

At present, spent nuclear fuel (SNF) assemblies discharged from US commercial power plants are placed into dry storage following a short cooling time (<10 years) in the plant’s spent fuel pool. The process of packaging the spent fuel into dry-storage canisters includes a drying step to remove residual water from the canister. During the drying process, the fuel rod cladding may reach temperatures as high as 400°C. Oak Ridge National Laboratory (ORNL) is performing destructive examinations of high burnup (HBU) (>45 GWd/MTU) SNF rods to address knowledge and data gaps related to extended interim storage and eventual transportation for disposal. The rods examined include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. Three rods were subjected to a thermal transient to assess the effects of decay-heat-driven high temperatures expected during vacuum drying of the fuel as it is prepared for interim dry storage. The examinations focus on the composite fuel rod performance, as compared with the performance of defueled rod cladding, and establish the baseline mechanical properties of a fuel rod before interim dry storage. The key results of these examinations are presented, including the measured mechanical and fatigue properties, observations of cladding hydrogen pickup and hydride reorientation effects on rod performance, effects of the simulated drying temperatures on rod performance, and general conclusions of SNF performance in extended interim dry storage and transport. The rods were found to be strong and durable in the expected loading conditions, even considering the formation of radial hydrides associated with vacuum drying. The combined testing provides a broad body of data supporting extended interim storage and transportation performance of HBU spent fuel.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Towards an Introspective Dynamic Model of Globally Distributed Computing Infrastructures

Large-scale scientific collaborations like ATLAS, Belle II, CMS, DUNE, and others involve hundreds of research institutes and thousands of researchers spread across the globe. These experiments generate petabytes of data, with volumes soon expected to reach exabytes. Consequently, there is a growing need for computation, including structured data processing from raw data to consumer-ready derived data, extensive Monte Carlo simulation campaigns, and a wide range of end-user analysis. To manage these computational and storage demands, centralized workflow and data management systems are implemented. However, decisions regarding data placement and payload allocation are often made disjointly and via heuristic means. A significant obstacle in adopting more effective heuristic or AI-driven solutions is the absence of a quick and reliable introspective dynamic model to evaluate and refine alternative approaches. In this study, we aim to develop such an interactive system using real-world data. By examining job execution records from the PanDA workflow management system, we have pinpointed key performance indicators such as queuing time, error rate, and the extent of remote data access. The dataset includes five months of activity. Additionally, we are creating a generative AI model to simulate time series of payloads, which incorporate visible features like category, event count, and submitting group, as well as hidden features like the total computational load—derived from existing PanDA records and computing site capabilities. These hidden features, which are not visible to job allocators, whether heuristic or AI-driven, influence factors such as queuing times and data movement.

kilic, Ozgur Ozan [Brookhaven National Laboratory ↗

Consumer safety-oriented scheduling of rotating power outages during heat waves

Extreme heat events have widespread effects on power systems, reducing available generation capacity, limiting transmission capabilities, and causing unusual demand patterns on the consumer side. As these combined effects expose bulk transmission systems to potential large-scale blackouts, utilities may be required to schedule and apply rotating outages, by temporarily and alternately disconnecting distribution substations to reduce overload. However, utilities lack mechanisms to inform these events, exacerbating the negative effects of heat waves on affected communities. This paper introduces a novel framework for scheduling rotating outages during heat waves while considering impacts on consumers’ safety. Instead of random sequential load shedding, we propose a methodology to rotate power outages considering a metric that quantifies the indoor overheating risk of groups of consumers during a power outage. The overheating risk is derived from a detailed building simulation using CityBES, where the buildings are modeled based on available data—use type, year built, floor area, number of stories, location—while presence of air conditioning and occupancy are calibrated from smart meter data. Based on the metric, an algorithm to schedule the rotating outages is applied to prioritize feeders for disconnection at each hour according to their overheating risk to meet a utility load reduction target. Applied to two substations and seven feeders in the Portland General Electric territory, the results show that this approach effectively leads to the lowest overheating risk during the resulting outage schedules, with an average 10.1% lower overheating compared to uninformed schedules.

Building thermal simulation↗

Biomechanical Analysis of Multilevel Posterior Cervical Spinal Fusion Constructs

Study Design: Controlled Laboratory Study Objective: To compare multilevel posterior cervical fusion (PCF) constructs stopping at C7, T1, and T2 under cyclic load to determine the range of motion (ROM) between the lowest instrumented level and lowest instrumented-adjacent level (LIV-1). Summary of Background Data: PCF is a mainstay of treatment for various cervical spine conditions. The transition between the flexible cervical spine and rigid thoracic spine can lead to construct failure at the cervicothoracic junction. There is little evidence to determine the most appropriate level at which to stop a multilevel PCF. Methods: Fifteen human cadaveric cervicothoracic spines were randomly assigned to 1 of 3 treatment groups: PCF stopping at C7, T1, or T2. Specimens were tested in their native state, following a simulated PCF, and after cyclic loading. Specimens were loaded in flexion-extension), lateral bending, and axial rotation. Three-dimensional kinematics were recorded to evaluate ROM. Results: The C7 group had greater flexion-extension motion than the T1 and T2 groups following instrumentation (10.17±0.83 degree vs. 2.77±1.66 degree and 1.06±0.55 degree, P <0.001), and after cyclic loading (10.42±2.30 degree vs. 2.47±0.64 degree and 1.99±1.23 degree, P <0.001). There was no significant difference between the T1 and T2 groups. The C7 group had greater lateral bending ROM than both thoracic groups after instrumentation (8.81±3.44 degree vs. 3.51±2.52 degree, P =0.013 and 1.99±1.99 degree, P =0.003) and after cyclic loading. The C7 group had greater axial rotation motion than the thoracic groups (4.46±2.27 degree vs. 1.26±0.69 degree, P =0.010; and 0.73±0.74 degree, P =0.003) following cyclic loading. Conclusion: Motion at the cervicothoracic junction is significantly greater when a multilevel PCF stops at C7 rather than T1 or T2. This is likely attributable to the transition from a flexible cervical spine to a rigid thoracic spine. Although this does not account for in vivo fusion, surgeons should consider extending multilevel PCF constructs to T1 when feasible. Level of Evidence: Not applicable.

Neurosciences & Neurology↗

PyKrev: A Python Library for the Analysis of Complex Mixture FT-MS Data

In this study, we present PyKrev, a Python library for the analysis of complex mixture Fourier transform mass spectrometry (FT-MS) data. PyKrev is a comprehensive suite of tools for analysis and visualization of FT-MS data after formula assignment has been performed. These comprise formula manipulation and calculation of chemical properties, intersection analysis between multiple lists of formulas, calculation of chemical diversity, assignment of compound classes to formulas, multivariate analysis, and a variety of visualization tools producing van Krevelen diagrams, class histograms, PCA score, and loading plots, biplots, scree plots, and UpSet plots. The library is showcased through analysis of hot water green tea extracts and Scotch whisky FT-ion cyclotron resonance-MS data sets. PyKrev addresses the lack of a single, cohesive toolset for researchers to perform FT-MS analysis in the Python programming environment encompassing the most recent data analysis techniques used in the field.

47 OTHER INSTRUMENTATION↗

Dataset of simulated vibrational density of states and X-ray diffraction profiles of mechanically deformed and disordered atomic structures in Gold, Iron, Magnesium, and Silicon

This dataset is comprised of a library of atomistic structure files and corresponding X-ray diffraction (XRD) profiles and vibrational density of states (VDoS) profiles for bulk single crystal silicon (Si), gold (Au), magnesium (Mg), and iron (Fe) with and without disorder introduced into the atomic structure and with and without mechanical loading. Included with the atomistic structure files are descriptor files that measure the stress state, phase fractions, and dislocation content of the microstructures. All data was generated via molecular dynamics or molecular statics simulations using the Large-scale Atomic/Molecular Massively Parallel Simulator (LAMMPS) code. This dataset can inform the understanding of how local or global changes to a materials microstructure can alter their spectroscopic and diffraction behavior across a variety of initial structure types (cubic diamond, face-centered cubic (FCC), hexagonal close-packed (HCP), and body-centered cubic (BCC) for Si, Au, Mg, and Fe, respectively) and overlapping changes to the microstructure (i.e., both disorder insertion and mechanical loading).

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

End-Use Savings Shapes: Public Dataset Release for Residential Round 1 [Slides]

The End-Use Load Profiles project created a public database of 900,000 individual building end-use load profiles. Load profiles were modeled to represent the U.S. building stock as it was in 2018, as nearly as possible based on the best available data. The End-Use Savings Shapes follow-on project adds measure impact profiles for energy efficiency and electrification packages to the public dataset. This presentation details the public dataset release on September 20, 2022.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

RAVIS: Resource Forecast and Ramp Visualization for Situational Awareness - An Introduction to the Open-Source Tool and Use Cases

The Resource Forecast and Ramp Visualization for Situational Awareness (RAVIS) is an open-source tool for visualizing variable renewable resource forecasts and ramp alerts for significant up/down ramps in renewable resource and the consequent net-load. The modular dashboard of RAVIS contains configurable panes for viewing- probabilistic time series forecasts, ramp event alerts on the look-ahead timeline, spatially resolved resource sites and forecasts, and system simulation and market clearing data such as transmission lines utilization, nodal prices and available generation flexibility. RAVIS uses a technology suite that is assembled to provide optimum visualization facility while maintaining a wide pool of potential deployment and client environments. The tool is designed to take advantage of web application technologies, open source visualization libraries and tooling. Utilizing this technology will enable deployment in any environment, using any operating system, and is scalable to much higher spatial and temporal scales of visualization. As a prototype of the tool and demonstrating a use case of variable renewable integration, RAVIS currently integrates site-specific solar power forecasts in the California Independent System Operator (CAISO) and Mid-continent ISO (MISO) footprint from the IBM WattSun forecasting platform, and also superimposes market simulation data for CAISO footprint from as in-house NREL market clearing tool. The tool has the ability to alert the viewer for excessive up or down ramps for both individual solar sites as well as regionally aggregated net-load ramps, and alerts can also be qualified with respect to available flexible generation. This report will provide an introduction to the RAVIS tool, and summarize the above mentioned capabilities, typical use cases and possible extensions of the tool. The RAVIS development team believes there are likely to be high economic and reliability benefits of integrating probabilistic forecasts of variable renewables into control center visualizations and improved ramp events situational awareness for system operators and forecasting teams in the ISOs and electric utilities in comparison with their business as usual practices.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

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↗

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↗

High-Temperature Multi-Process Sensor Development for a PC-Fired Unit

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↗

High-Temperature Multi-Process Sensor Development and Demonstration at Coalfired Power Plants

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↗