TECHNOLOGY MATURATION OF WIRELESS HARSH-

ENVIRONMENT SENSORS FOR IMPROVED CONDITION-BASED

MONITORING OF COAL-FIRED POWER GENERATION
Motivation Project Structure & Implementation
M. Pereira da R. J. Cunha1, 2,
G. A. Lad1, 2, Harkay 2, Maskay1, 2
1University of Maine, Orono, Maine, U.S.A
COAL: U.S. Energy Information Administration (EIA)  Project Tasks:
2Environetix Technologies Corporation, Orono, Maine, U.S.A.  TASK 1 – Project Management & Planning
 U.S.A  21% of the world’s proven recoverable
reserves of coal (255.8 billion short tons)  TASK 2 – Technology Transition & Adaptation: High
Temperature Wireless SAW Sensor Technology in
 This is only 6.5% of the potential total coal resources Surface Acoustic Wave (SAW) Technology UMaine/Environetix Previous Experience Harsh Coal-fired Power Plant Environments
 HUGE SOURCE OF ENERGY FOR THIS COUNTRY!  TASK 3 – Implementation and Testing of Mature
 Class of Micromechanical Systems (MEMS) Collaboration with Penobscot Energy Recovery Company Prototype Wireless Sensor System within Power Plants

 Electronic platform: electrical signal translated into (PERC) Power Plant in Orrington, ME  TASK 4 – Protective Coatings and Piezoelectric Thin
Films for Improved Sensor Packaging & Performance
microwave acoustics using a piezoelectric substrate  PERC  Municipal Solid Waste (MSW) Power Plant
 TASK 5 – Development of Prototype SAW-based Strain
 Delay line and resonators: typical SAW structures used for  Goal  Implement a Wireless Temperature Monitoring Sensor
sensor applications System(s) at the MSW power plant Milestone Planned Completion Milestone Title
 Interdigitated transducers (IDTs) used for wave generation; M1 1st quarter of Year 1 Kick-off Meeting with DOE / NETL Program Officer
reflector electrodes used for acoustic wave energy trapping Definition of Target Locations to Install Prototype
 M2 4th quarter of Year 1
Wireless HE SAW Sensor System
output W acoustic
interdigital absorber M3 1st quarter of Year 2 Wireless Communication Planning and Testing
June 2017 Monthly Energy Review, U.S. Energy Information Administration transducer
Fabrication of Prototype Wireless HE SAW Sensor
(EIA), DOE/EIA-0035(2017/6)
M4 3rd quarter of Year 2
piezoelectric
System
 Coal usage  diminishing since the mid-2000s : input
material
Installation of Specific Prototype Sensor System in
interdigital
SAW
M5 4th quarter of Year 2
 Coal-fired Variable Operations and Maintenance transducer z x Identified Power Plant Locations
d
 Testing of Specific Prototype Sensor System in
(VOM) consistently HIGHER than Natural Gas
acoustic
absorber
y
M6 1st quarter of Year 3
Identified Power Plant Locations
Refinement of Sensor System Performance and
 Emissions M7 4th quarter of Year 3
Additional Testing
Busbars

 High Coal availability in the U.S. calls for: http://www.rfwireless-world.com

Identification of the Best Thin Film Dielectric
M8 1st quarter of Year 3 Coatings for Packaging of Sensor in Harsh-
 New Advanced Technologies for use in harsh  Typical operating features: Environment
environments  vp  3.103 m/s << c= 3.108 m/s (5 order of mag.  size )  Power plant conditions: Identification of the Best Piezoelectric Materials for
M9 2nd quarter of Year 3 Enhanced Sensor Manufacturability and Integration
 Advanced Sensors for Condition Based  Frequency range: 50 MHz to a few GHz (range  Temps  900°C (1650°F) with Sensor Antenna
Maintenance (CBM) determined by size & lithography)  Highly erosive/corrosive exhaust gases M10 2nd quarter of Year 3
Field Testing of Wireless Temperature Sensor Arrays
in Selected Power Plant Locations
Advanced Sensors:  Respective  (vp =  . F)  from 60µm to 1.5µm ¾” Schedule 40 Hastelloy
thermocouple tube after ~6 mo M11 2nd quarter of Year 3 Demonstration of Strain Sensor
Operating Maintenance  minimum feature size  /4  ~ 15µm to 0.4µm
Emissions
Cost Cost  Low cost in high volume production  Wireless HE/HT Sensor Array tested at Economizer M12 4th quarter of Year 3
Final Demonstrations in Coal-fired Power Plants and
Final Project Reporting Preparation to DOE / NETL
 Reproducible manufacturing based on semiconductor Example of wireless temperature
fabrication capabilities
monitoring over 5 weeks  Current Activity Status:
Goals and Objectives  Kick-off meeting DOE on February 22, 2018
 Environetix subcontract executed on March 21, 2018
GOALS  Contact & Coordination with Duke Energy / PERC/
SAW Sensors in Harsh Environments Other Coal-based Power Plants
 Usage of Harsh-Environment (HE) High-Temperature
 Hiring staff for project support at UMaine
(HT) Wireless Surface Acoustic Wave (SAW) Sensor
Technology to:  Engaging Grad and Undergrad students

  Reliable maintenance through CBM of critical

coal-based power plant equipment
Conclusions
Wireless SAW sensor tests in
monopole
  Cost-effective efficiency of power plant 6 dipoles + interrogating
power plant harsh environment
operations  SAW technology can be used to measure a variety of sensor carried out over 2 years  Project initiated within the past 2 months.
SAW Sensors antenna
parameters: temperature, pressure, torque, strain, gas  Presented Project Background: Motivation, Goals, &
  Power Plant Safety  Wireless HE/HT Sensor Array tested in Boiler
 Small sensor footprint 300 MHz Objectives
  HE/HT Wireless SAW Sensor Technology SAW Sensor  PERC Indicated the need for:  Provided SAW Technological Overview and HE/HT
Readiness Level (TRL) via test & implementation  Robust and stable over long-term
 Placement of sensor array on Boiler tubes for CBM SAW Sensor Background
 Varying detection mechanisms: mass
 Locate blockage  optimally aim steam/soot blowers  UMaine/Environetix are under current discussions with
OBJECTIVES loading, absorption, stress, changes in film
coal power plant collaborators to be selected as test bed
thickness or material properties
 HE/HT Wireless Surface Acoustic Wave (SAW) for technology demonstration and advancement
Temperature Sensors  CBM in Coal Power Plants  Existence of substrates for high temperature applications,  Described Project Structure & Implementation
such as the langasite (LGS)
 Improvement in the packaging of SAW temperature  Tasks & Milestones
sensors & antennas  LGS : 1470°C Melting point  Current Activity Status
 Advancement in piezoelectric films and strain sensors Advantages of SAW Sensors:
Wireless, battery-free, robust, passive operational
 Wireless communication protocols & signal
capability leading to reduced installation &
processing refinements
maintenance cost DOE / NETL Project DE-FE0031550
 Technology validation and transition to coal-based Program DE-FOA-0001728:
power plants Complexity Reliability Size Advanced Combustion Systems (ACS): Existing Plant
Improvements and Transformational Technologies