Distributed Wireless Antenna Sensors for Boiler Condition Monitoring

Award #: DE-FE0023118Duration: 1/1/2015-12/31/2017

Organizations: University of Texas ArlingtonUC San Diego

Outline

Team membersTechnical background/motivationPotential significanceRelevancy to fossil energyPlanned tasks - SOPOProject milestones, budget, and scheduleProject statusQ&A

2

Team Members - PIs

Haiying Huang, PIProfessor of Mechanical & Aerospace Eng.

Research Interests:Sensors (wireless, optical fiber, ultrasound, etc.)Mechanics of Materials

Jian Luo, site-PI (UCSD)Prof. of NanoEngineeringand Materials Sci. & Eng.

Research Interests:Materials processing & characterizationInterfacial engineering

Ankur Jain, Co-PIAssistant Professor of Mechanical & Aerospace Eng.

Research Interests:Heat Transfer, Thermal Measurements, MicroscaleThermal Transport.

3

Team Members – Students & Post-doc

Vivek VishwakarmaUTA PhD student (2012)BS: Indian Institute of Technology 2012Thermal measurement

Tao HuPost-doc, UCSDPhD: City Univ. of Hong Kong, 2011Post-doc: UC Davis Material design and fabrication

Jun YaoUTA PhD student (2012)ME: Univ. of Shanghai for Sci. &Tech, 2012BE: Southeast Univ., 2009Wireless interrogation of patch antenna sensor

Franck Eric TchafaUTA PhD student (2014)BS/MS: City Univ. of London 2010Sensor design & characterization

4

Distributed antenna sensors

Tx/Rx antenna

Interrogation antenna

Tx/Rx antenna

Antenna sensor array

Objectives & OverviewRealize distributed conditioning monitoring of stream pipes up to 1000 oC• Monitor temperature and strain distribution of steam pipes• Detect soot accumulation on steam pipes

5

Potential Significances

Introduce novel wireless sensor concept for high temperatureapplications High temperature material development Wireless interrogation without electronics Multi-modality sensing (strain, temperature, soot accumulation) Sensor multiplexing for distributed sensing

Lay the foundation for producing a family of high temperaturesensors that can monitor pressure, flow, gas, corrosion etc.

Advance understanding and control of high temperaturedielectric properties at gigahertz frequencies

6

Relevance to Fossil EnergyCondition Monitoring of Steam Pipes

Enhance safety (high temperature, high pressure, corrosive environment)Improve heat transfer efficiency by optimizing soot cleaning

Distributed Multi-variant SensingEnable detailed condition monitoringof boilersGain fundamental understanding ofcombustion and heat exchangeprocessesHelp develop and refine simulationmodelsAchieve better design and moreefficient operation of boilers 7

Microstrip Patch Antenna

Radiation patch

Ground plane

-30

-25

-20

-15

-10

-5

04.5 4.8 5.1 5.4 5.7 6 6.3

Ret

urn

Los

s (dB

)

Frequency (GHz)

f = antenna resonant frequencyc = speed of lightεr = substrate dielectric constant L = patch dimension along current directionL

cfrε2

=

8

Patch Antenna for Sensing

LLfff eff

effδδε

εδ

∂∂+

∂∂=

Lcfeffε2

=

LL

ff

eff

eff δεδεδ −−=

21

Strain: change dimensions of radiation patch δL/LSoot accumulation: change effective dielectric constant δεeff/εeffTemperature: changes both δεeff/εeff and δL/L

Superstrate ε2

Substrate ε1

( )112211 1 qqqqreff −−++= εεε

9

Prior Work – Strain Sensing

y = -0.98x + 8E-18R² = 1

y = -0.8936x + 0.0003R² = 0.9921

-0.03

-0.025

-0.02

-0.015

-0.01

-0.005

0

0 0.01 0.02 0.03

AnalyticalMeasuredLinear (Analytical)Linear (Measured)

Strain (%)

Freu

qnec

y Strain sensitivity: ~ 1 ppm/με

Strain resolution: 20 με

1015 mm

12.7

5 m

m

Prior Work – Temperature Sensing

Metal baseRadiation patchDielectric substrate

Microstriptransmission

line

SMA connector

00.0010.0020.0030.0040.0050.0060.0070.0080.009

0.01

0 10 20 30 40 50 60 70

δf10

/f 10

Temperature change, δT (οC)

AluminumCopperSteel

Estimated errors: 2.2oC

Commercial high freq. dielectric substrateCTE: 17 ppm/oCδεr/δT: -160 ppm/oC

11

Challenge #1 & Potential SolutionsChallenge #1: coupled effects of strain, temperature, soot on antenna radiation characteristics

Potential Solutions: Tailor material properties to isolate the effectsExtract two parameters simultaneously from two resonant frequencies of a single antenna sensorExtract all three parameters simultaneously using parameter identification

12

Wireless Interrogation

Frequency

P BS

ModulatorWireless reader

Ptx

PBS

LoadloadWireless reader

Ptx

PBS

Frequency

P BS

13

Prior Work – Wireless & Sensor Multiplexing

Interrogation antenna

Interrogation distance: > 1 m

8.6 mm

Distributed sensor array

Modulation circuit

14

Challenge #2 & Potential SolutionsChallenge #2: wireless interrogation without electronics

Solutions: Use a long transmission line

Implement FMCW-based time gating technique

Wireless reader

Ptx

PBS

Antenna sensor array

Long delay line

Wireless reader based on FMCW

Time Gating

Ptx

PBSHigh Q Antenna

sensor array15

Planned Research Tasks

Task 1.0 Project Management and Planning

Task 2.0 Realize Flexible Dielectric Substrates

Task 3.0 Establish Sensor Design and Analysis Tools and Algorithms

Task 4.0 Characterize Sensors at High Temp.

16

Task 1.0 Project Management and Planning

Hold kick-off meeting Modifications to the Project Management Plan Reporting schedule Plan for regular project meetings

Revise & submit Project Management Plan

Prepare & submit required NEPA documentation

17

Task 2.0 Realize Flexible Dielectric Substrates

Subtask 2.1 – Design dielectric properties of high temperature materialsSubtask 2.2 – Synthesize flexible dielectric substratesSubtask 2.3 – Characterize properties of substrate materials Microstructure Dielectric Property Mechanical Property

Deliverables:Materials and sintering recipesFlexible dielectric substrates with desired material propertiesValidated material dielectric property measurement method

18

Subtask 2.1 – High Temp. Material DesignPreliminary design Silica (SiO2) as starting point: well established processing route; Binary SiO2-TiO2 ceramics: good sinterability and tunable dielectric

constant; More exotic oxides, e.g. CaTiO3 and BaZrO3, ZrO2 and YSZ (Y2O3-

stabilized ZrO2): further improve the dielectric properties

Further development (a high-risk and high-return effort) Doping and interfacial engineering to improve the processability,

microstructure, and dielectric property via controlling grain boundaries

Various grain boundary structures that may control sintering, microstructural development and dielectric properties [Figure courtesy of Dillon & Harmer, see an Overview article by

Cantwell, Tang, Dillon, Luo, Rohrer, and Harmer, Acta Materialia, 62: 1-48 (2014) for details] 19

Subtask 2.2 – Synthesize Flexible Substrates

Sol-gel method and tape casting Uniformly layer of ~10-200 μm thick Select sintering aids/dopants to control both

processing & properties

Selection of electrode materials Ni as primary electrode material: high-temperature stability, good

oxidation, corrosion resistance Ultra-thin Au film: sufficiently stable at high temperatures (but more

expensive than Ni; “ultra-thin” to reduce the cost)

“Flashing sintering” (a high-risk and high-return effort) Reduction of sintering temperatures Low-temp. co-sintering of the metallic electrodes and dielectric oxides

20

Subtask 2.3 – Characterize Material Properties

Microstructure characterization Microstructure and compositions Grain boundary structures at atomic scale

Dielectric property characterization Resonant frequency and fractional

bandwidth (Q factor) of the ring resonator Repeatability at elevated temperature

Mechanical property characterization Detect cracking, spalling, etc. Conformability

21

Task 3.0 Sensor Design and Analysis

Subtask 3.1: establish efficient antenna simulation modelSubtask 3.2: develop multi-variant regression algorithmsSubtask 3.3: perform parameter studies to optimize dielectric propertySubtask 3.4: design distributed antenna sensor array

Deliverables: Cavity model of antenna sensorNonlinear regression algorithm for multi-variant analysisOptimal design of antenna sensor array

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Subtask 3.1: Establish Efficient Antenna ModelSimulation model is needed for Parametric studies Multi-variant analysis

Cavity model Cavity bounded by top & bottom

electric walls Magnetic wall all along the

periphery.

Governing Equations( ) ( ).,, = m n mnmnz yxAyxE ψ

∞

=

∞

= −−=

0 0 2200

2

00),(

m nmn

mn

mnin G

kkyxIjZ ψωμ

Electric walls

Magnetic walls

23

Subtask 3.2: Develop Multi-variant Analysis

Circumferential strain onlyTM10 resonance: thermal expansion & sootTM10 resonance: strain, thermal expansion & soot

TM10

TM01

+−=Δ

−

−−=

−Δ=

−Δ=

LT

L

LT

LT

ff

kT

ff

ff

Tkff

Tkff

εδ

δδυ

ε

υεδ

εδ

10

10

01

01

10

10

01

01

10

10

1

11

Temperature/strain sensor 24

Material properties

Simulation model

Temperature

Soot accumulation

Strain

Parameter Identification

Measured S-parameter

Simulated S-parameter

Subtask 3.2 – Parameter Identification

Extract all three parameters from one single S-parameter measurementAdjust input parameters to match simulated & measured S-parameters

25

Subtask 3.3: Optimize Dielectric Property

Single-modality: enhance sensitivity to temperature or sootMulti-modality: balance sensitivity to temperature, strain, soot

LL

ff

eff

eff δεδεδ −−=

21

sootsoot

effeffeff H

HT

Tδ

εδ

εδε

∂∂

+∂

∂=

Teff

∂∂ε

Temperature only

Soot

on

ly

Multi-modality

26

Subtask 3.4: Achieve Distributed Sensing

Tx/Rx antenna

Antenna sensor array

Tx/Rx antenna: broadband Antenna sensors: narrowbandVarying delay line lengthFrequency division and/or time division multiplexing

Time/Freq.

Am

plitu

de

ith antenna signal

27

Task 4.0 Characterize Sensor at High Temp.

Subtask 4.1: design and implement temperature chamberSubtask 4.2: realize wireless interrogation of antenna sensors without electronicsSubtask 4.3: evaluate distributed wireless sensing at high temperatures

DeliverablesDemonstrate wireless interrogation of passive antenna sensors Validate sensing capability of antenna sensors at high temp.

28

Subtask 4.1: Implement Temperature Chamber

Model: Lindberg/Blue M BF51732PCTemperature range: 100-1200oCChamber dimension: 11 x 12 x 11 inches Vertical lift doorA refractory brick wall will be constructed & placed in front of the lift doorMetal casing may be removed

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Subtask 4.2: Realize Wireless Interrogation

Wireless Interrogator

Tx

Rx

FMCW Synthesizer

Homodyne Detector

f2 , f3

fi (t)

Antenna Sensor Array

Tx/Rx

Sign

al F

req.

Time

Clutter

Reference

Sensor signal

f1

f2

f3

IF F

req.

f2 -f1f3 -f1

30

Δf2 , Δf3

Δfi are separated based on travel distance

Subtask 4.3: Evaluate Distributed Sensing

Close pipes pressurized at different pressure levelLocal thinning of pipe wall to imitate corrosionEffects of soot & moisture on antenna sensor radiationWireless interrogation outside & inside of refractive brick wall

Temperature chamber

Wire

less

re

ader

Temperature chamber

31

Project OutcomesMethodology to realize low-cost antenna sensor arrays Sustain high temperature and harsh environments Cover a large area and conform to curved surfaces Measure multiple physical parameters at multiple locations

Wireless interrogation techniques without electronics Capable of interrogating distributed antenna sensors Reasonable interrogation distance, resolution, and speed

Material and fabrication recipes and fabrication techniques Robust against high temperature and harsh environment Controllable dielectric properties Flexible substrate

32

SOPO – Schedule

33

SOPO – Milestones2/17/2015: revised Project Management Plan approved by theDOE-NETL technical contact4/30/2015: document material selection and synthesis recipe11/30/2015: demonstrate fabrication of flexible dielectricsubstrates8/31/2016: finalize material recipe6/30/2016: demonstrate nonlinear regression algorithms12/31/2016: demonstrate distributed antenna sensor array9/30/2016: demonstrate temperature chamber3/31/2017: demonstrate wireless interrogation of passive antennasensors12/31/17: validate sensor performance at high temperatures

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SOPO – Budget

Project Member Year 1 (2015) Year 2 (2016) Year 3 (20177)Haiying Huang $98,031 $80,060 $82,642Ankur Jain $16,615 $19,040 $17,983Jian Luo (UCSD) $34,697 $28,117 $22,126

Total budget: $399,311 ($314,371 UTA + $84,940 UCSD) Salary & F.B.: $149,254 (PIs, Post-doc, PhD & undergrad. student) Equipment: $5,611 for a furnace up to 1200oCTravel: $14,988M&S: $14,988Subaward: $84,940Tuition: $21, 305Conference registration fee: $2,745Overhead: $106,214

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Project Status

Official starting date: 1/1/2015

Funding in placeStudents & post-doc recruited

Kick-off meeting in progress

36

Question & Answers

37Thanks for your attention!