Instrumentation, Controls,
and Automation
Winter 2009 www.epri.com
Manager’s Message
Welcome to the first newsletter for the Instrumentation,
Controls, and Automation program of EPRI. During the past
year, there have been a number of exciting accomplishments
in the program:
• Continued growth of the Fleetwide Monitoring Interest
Group (FWMIG), in terms of number of members and
attendees (85 at the October 13–15, 2009, meeting).
• Development of prototype software Asset Fault Signature
Database (1017523, available December 31, 2009) for
storage and retrieval of patterns of fault signatures.
• Completion of site radio frequency testing and wireless
mesh networking for condition-based sensing in a large
coal-fired power plant and documentation of results in
two reports, Demonstration of Wireless Motes for Fossil
Plant Monitoring (1015714) and Program on Technology
Innovation: Wireless Mesh Sensor Networks for Fossil Plant
Monitoring (1016188).
• Completion of testing of automated tuning techniques
to facilitate improved control loop tuning and
documentation of results in Automated Boiler Control
System Tuning Demonstration (1020370, available
December 31, 2009).
continued on page 2
Contents
Asset Fault Signature Database Overview.................................. 1
Inter-Control Center Communications Protocol Benefits
Assessment............................................................................. 5
Survey of Commercial and Near-Commercial High-Temperature
Strain Sensors......................................................................... 7
Fleetwide Monitoring Interest Group Web Site Instructions.......... 12
2010 Program 68 Overview.................................................. 15
Summary of the Fall 2009 EPRI Fleetwide Monitoring Interest
Group Meeting..................................................................... 17
Upcoming Events.................................................................. 17
P68 Product List.................................................................... 18
Contacts.............................................................................. 20
11018333
Asset Fault Signature Database
Overview
Maintaining the high reliability of power-generating plants
requires efficient access to unambiguous information on plant
asset performance and condition. Processing this information must
be efficient and timely in order to make cost-effective decisions
regarding maintenance priorities. Equipment monitoring systems
are now commonly used to detect and trend anomalies in process
parameters that are often associated with component degradation.
There remains an unmet need for accurate diagnoses of plant asset
health using all available information, such as plant monitoring
data, results of technology examinations, operator rounds, and
engineering assessments. EPRI’s Asset Fault Signature (AFS)
Database is under development, with its purpose to catalog, store,
and retrieve asset fault information used to interpret changes
in observed plant parameters and to advise users on the likely
cause of anomalies. These diagnoses will provide a basis for risk-
informed maintenance decisions.
General Description
The AFS Database software will be employed to enable case-
based reasoning by a Diagnostic Advisor software product to be
developed concurrently by EPRI. The Diagnostic Advisor can
use a combination of actual fault signature patterns derived from
experience and others that are theoretical to the design of the
equipment as the basis for its diagnostic reasoning. These two
types of fault signatures can be used interchangeably and in
combination. Based on attributes of a new observed fault pattern,
the reasoning algorithm determines a best match from the AFS
Database, which becomes the basis for a diagnosis. Experience-
and design-derived signatures can be added to the database or
updated as new information is acquired, giving the AFS Database
a capability to learn new signatures and improve continuously
with use. When the Diagnostic Advisor and the AFS Database
become operational across the industry, they will serve an
increasingly important role in industry knowledge retention by
capturing cause-effect relationships associated with equipment
degradation.
continued on page 2
Manager’s Message
continued from page 1
• Completion of a case study for implementing automation
logic on a feedwater system startup for a large combined-
cycle plant, with recorded web casts, white papers, and
presentations available on the program collaborative web
site. (On www.epri.com, go to “EPRI Collaboration,”
then “Instrumentation and Control.”)
This newsletter summarizes results of past and current
projects and provides an overview of projects that will be
completed in 2010. The first article describes the recently
prototyped software Asset Fault Signature Database. The
second article, “Inter-Control Center Communications
Protocol Benefits Assessment,” describes a previously
completed EPRI/Southern Company tailored collaboration
project. “Survey of Commercial and Near-Commercial High-
Temperature Strain Sensors” describes results of a literature
survey on strain gauges. The fourth article, “Fleetwide
Monitoring Interest Group Web Site Instructions,” contains
instructions on how to navigate to the FWMIG web site.
The final article, “2010 Program 68 Overview,” provides
an overview of the membership-funded Instrumentation,
Controls, and Automation program for 2010.
For more information on the Instrumentation, Controls, and
Automation program, the FWMIG, or any of the articles in
this newsletter, contact Aaron Hussey.
Aaron Hussey
Program 68 Technical Lead
704.595.2509
ahussey@epri.com
Instrumentation, Controls, and
Automation Newsletter
Is published by the Electric Power Research Institute's (EPRI's)
Instrumentation, Controls, and Automation Program.
1300 West W.T. Harris Blvd., Charlotte, NC 28262,
fax: 704.595.2862, Program 68 Technical Lead, Aaron Hussey,
704.595.2509, ahussey@epri.com.
Instrumentation, Controls, and Automation 2 Winter 2009
11018333
Asset Fault Signature Database Overview
continued from page 1
Objectives
The use of all available information relating to plant asset
condition is considered an important objective for any
proposed diagnostic process. The collaborative development
and use of experience-derived fault signatures as elements of a
comprehensive AFS Database will require a unifying standard
format for the collection of industry data for use by the fleet of
operating units. EPRI is developing the AFS Database to provide
this unifying standard. The AFS Database software is a stand-
alone knowledge base product suitable for use by diagnostic
monitoring software applications, such as EPRI’s Diagnostic
Advisor product (in development by Expert Microsystems). In
the Diagnostic Advisor application, the AFS Database is designed
to be an integral module within EPRI’s PlantView Enterprise
Asset Management (EAM) product (developed by PowerVision
in Newark, New Jersey), working in coordination with a risk-
informed maintenance product (in development by EPRI), as
well as with existing PlantView modules.
An asset is defined as a physical site, unit, system, item of
equipment, or component. A fault is defined as a condition or
state of an asset that is a precursor to a failure of that asset to
perform its required function. A fault feature is defined as a state
of an item of plant information that is an indicator for a specific
fault. A fault signature is defined as a combination of a specific
fault type and a set of associated fault features in the context of a
specific asset type.
The objectives for the AFS Database software are as follows:
• To enable effective collection, organization, and retrieval of
experientially derived fault signatures and design-theoretical
fault signatures for power plant assets that can provide a basis
for diagnostic reasoning. An experience-derived signature
captures the signature of a fault actually experienced in the
operation of an industry-deployed asset. A design-derived
signature captures the signature of a fault defined in the EPRI
preventive maintenance (PM) basis database, in a failure modes
and effects analysis, or by design analysis or simulation.
• To capture the fault signatures in such a way that they can be
used and exchanged across the power industry. This role of the
AFS Database has very high value because it is unlikely that a
single unit, plant, or utility will experience all faults possible
during an asset’s lifetime.
continued on page 3
Asset Fault Signature Database Overview
continued from page 2
• To enable plant staff and subject matter experts to collect and
save their diagnostic and operational experience in the AFS
Database while using the Diagnostic Advisor as part of their
troubleshooting and equipment assessment processes.
• To enable a learning application that improves over time as
new fault conditions are discovered and cataloged in the AFS
Database by the Diagnostic Advisor’s users.
• To provide a capability of operating alternatively within the
architecture of multiple EAM software tools, wherein PlantView
will be the first such application.
The Diagnostic Advisor will use the AFS Database to generate
a specific diagnosis of an equipment malfunction or impending
breakdown, providing an explanation for the fault indications
observed. The goal is to detect and identify the fault condition
before the equipment is disabled or fails to meet its service
requirement. The most likely fault condition will be determined
and reported, along with a prioritized list of alternative
explanations. This capability will enable an automated
implementation of predictive maintenance in lieu of calendar-
driven PM.
Users
There will be three principal users of the AFS Database. The
users and their attributes are as follows:
• Diagnostic software includes EPRI and vendor-provided
diagnostic software applications and EAM tools. Diagnostic
software will query the AFS Database using structured query
language (SQL) to retrieve fault signatures and the related
metadata. Diagnostic software might also have the ability to
update a local (site) copy of the AFS Database with new or revised
fault signatures. This updating capability is a planned feature of
the EPRI Diagnostic Advisor software. The diagnostic software
will provide the interface used by subject matter experts or plant
staff to access the AFS Database.
• The site database administrator is responsible for maintaining a
subscriber site installation of the AFS Database. A subscriber site
is a power plant or a utility company that subscribes to use the
AFS Database and has the option to receive database updates
from EPRI on a periodic basis. The site database administrator
will control access to the database, including access to update
or to add new fault signatures. The site database administrator
will have the ability to export updated or new signatures for
transmittal to EPRI, to load database updates received from
EPRI, and to produce management reports describing the use
and performance of the database.
Instrumentation, Controls, and Automation 3 Winter 2009
11018333
• The EPRI database administrator is responsible for maintaining
the AFS master database. Copies of the AFS master database will
be provided by EPRI to subscribing user sites and will contain
the industrywide repository of AFS knowledge. The EPRI
database administrator will control the content and distribution
of AFS Database copies to user sites. EPRI expects to collect
an expanding database of fault signatures from industry over
time and distribute these as AFS Database updates on a periodic
subscription basis.
Scope
The AFS Database will be implemented as a module within
and a subprocess of an enhanced EAM system. The initial
implementation will be performed within the PlantView EAM
product developed by PowerVision for EPRI. In this use, the
Diagnostic Advisor software will perform its diagnosis functions
using the AFS Database as a case base. The AFS Database is
expected to evolve with time as new fault signatures are added to
the database. This will enable the database to learn these new fault
signatures and improve the accuracy of the diagnosis continually
as the AFS Database evolves. The Diagnostic Advisor and the
AFS Database fit into the overall architecture of an enhanced
EAM system as shown in Figure 1 on page 4.
The AFS Database will serve the Diagnostic Advisor, which will
be a multiuser web-based application suitable for integration
with industry-leading EAM applications. The AFS Database will
communicate with the Diagnostic Advisor through a dedicated
SQL connector. Analytical capability will be provided by a core
Diagnostic Advisor reasoner module that is integrated with
PlantView using a general purpose user interface application
programming interface (API). This architecture is diagramed in
Figure 2.
The Diagnostic Advisor reasoner will acquire plant information
from a variety of sources, each of which will likely require a
unique software interface. The Diagnostic Advisor’s data source
API will provide a unified view of the many possible data sources
to the Diagnostic Advisor reasoner and will encapsulate and hide
the unique characteristics of each data source. Data source plug-
ins will serve the purpose of adapting each specific user-provided
data source to the Diagnostic Advisor’s data source API. The
local database created and used by the Diagnostic Advisor will
communicate also through a dedicated SQL connector.
continued on page 4
Asset Fault Signature Database Overview
continued from page 3

Figure 1. The AFS Database deployed in an EAM system Figure 2. The Diagnostic Advisor interfaces

Database Management Interfaces Schedule

The AFS Database additionally will provide a dedicated graphical The AFS Database will be delivered first as a prototype to
user interface for the purpose of database administration and for members of EPRI’s Program 68, Instrumentation, Controls, and
adding fault signature information to the database. Two levels Automation, and Program 69, Maintenance Management and
of dedicated user interface will be required: the site database Technology. After collecting feedback through mid-2010, a final
administrator and the EPRI database administrator. version will be produced by end-of-year 2010. Figure 3 depicts the
schedule for the AFS Database product delivery.
The site database administrator will be responsible for
maintaining a subscriber site installation of the AFS Database.
A subscriber site is a power plant or a utility company that
subscribes to use the AFS Database and has the option to
receive database updates from EPRI on a periodic basis. The
site database administrator will control access to the database,
including access to update or to add new fault signatures The site
database administrator will have the ability to export updated Figure 3. The AFS Database schedule
or new signatures for transmittal to EPRI, to load database
updates received from EPRI, and to produce management For more information, contact Aaron Hussey, 704.595.2509,
reports describing the use and performance of the database. The ahussey@epri.com.
site database administrator will expect a full-function, intuitive,
graphical user interface to enter and manage fault signature
information.
The EPRI database administrator will be responsible for
maintaining the AFS master database. Copies of the AFS master
database will be provided by EPRI to subscribing user sites and
will contain the industrywide repository of AFS knowledge.
The EPRI database administrator will control the content and
distribution of AFS Database copies to user sites. EPRI expects
to collect an expanding database of fault signatures from industry
over time and to distribute these as AFS Database updates on a
periodic subscription basis.
Instrumentation, Controls, and Automation 4 Winter 2009
11018333
Inter-Control Center Communications Protocol Benefits Assessment
Introduction
In mid-2006, Southern Company Services (SCS) established
a tailored collaboration project with EPRI to provide support
and testing of a pilot project for unit dispatch. Working with
Foxboro and LiveData, SCS implemented Inter-Control Center
Communications Protocol (ICCP) on its Plant Branch Unit 4
to test the new technology as compared with the traditional
remote terminal unit (RTU) technology. EPRI contracted the
Instrumenation and Control Center in Harriman, Tennessee to
assist in development of test procedures, testing of load ramps,
and the analysis of test data. The pilot project objective was
to test and compare legacy technology against direct digital
communication between the SCS dispatch facility and the
plant distributed control system (DCS). SCS unit dispatch
uses pulse-type signal communication over analog telephone
lines. The pulse-type control is implemented with a traditional
RTU connected to the energy management system (EMS) and
hardwired inputs and outputs connected to the plant control
system. Set-point control using digital communication uses a
direct network connection between the EMS and Plant Branch
Unit 4 control system’s workstations. The set-point control uses
the ICCP developed by EPRI, which is widely used for dispatch
system communications.
The ICCP is an international standard (IEC6080–6 TASE.2)
to enable exchange of real-time data between the control centers
of different utilities over wide area networks (WANs). ICCP–
TASE.2 is being used worldwide to provide real-time data
exchange among control centers, substations, power plants,
supervisory control and data acquisition, and metering equipment
within the electric and gas utility industries. SCS contracted with
Invensys and its partner LiveData to implement ICCP on Plant
Branch Unit 4 in Milledgeville, Georgia. This connection is
through direct digital connection over the corporate local area
network/WAN to central dispatch in Birmingham, Alabama,
to test and compare set-point control against the existing pulse-
type control. Three testing phases were planned, each one week
in duration. The first and third weeks would use the pulse-type
control, or existing configuration, and the second week would
use the new set-point configuration. For the morning and
evening load ramps, central dispatch would move the unit in
as near identical a fashion as practical during the week for each
configuration. Plant process and EMS data would be collected
at 5-second or faster intervals for analysis and comparison of the
two methodologies.
Instrumentation, Controls, and Automation 5 Winter 2009
11018333
Objectives of the Test Program
The objectives of the test program are as follows:
• To compare the performance of unit dispatch using both the
ICCP set-point implementation and the existing RTU/pulse
implementation. Performance criteria will include maximum
dispatch rate, dispatch tracking accuracy, and steady-state
accuracy.
• To compare the performance of the two methods using both
normal dispatch operation and a specific load ramp test profile.
• To provide analysis of the projected benefits of the set-point
control implementation.
Equipment Configuration
The SCS EMS was supplied by Harris Controls in 2000 and is
installed in Birmingham, Alabama. Systemwide unit dispatch is
through RTUs located at each plant connected to the EMS over
dedicated communication lines that are combinations of fiber-
optic and microwave technologies. Figure 1 shows the ICCP-
based dispatch configuration.
Figure 1. SCS ICCP-based dispatch configuration
Figure 2 on page 6 shows the existing pulse dispatch structure.
The RTU is connected to the plant DCS by hardwired analog
and discrete inputs. The RTU outputs two discrete signals to
the DCS for raise and lower commands. In addition, there are
four discrete rate signals, T1 through T4. The T1 through T4
rates are typically set at 1%/min, 2%/min, 3%/min, and 4%/min,
respectively. Only one of the rate signals can be true at a time.
The DCS integrates the raise/lower pulses at the selected rate to
develop an internal load set point. The cycle time of the pulse-
type control is 6 seconds.
continued on page 6
Inter-Control Center Communications Protocol Benefits Assessment
continued from page 5
SC Gen
EMS Firewall
Harris
Company network
Firewall
Foxboro workstation
Plant branch 4
Figure 2. SCS four-pulse dispatch configuration
Statistical analysis of the load response for each test and for
several days of normal operation revealed minor differences in
performance. However, these differences are not believed to
be related to the actual control method in service. Rather, the
response differences are believed to be caused by minor variations
in the logic at the plant that interprets the signals from the
dispatch system.
The testing also identified several areas where further investigation
may be warranted. One of these is the load rate of change above
480 megawatts (MW). The set-point and pulse methods did not
use the same rates in this region with the set point using 1.3 MW/
min and the pulse using 6.0 MW/min. Also, there is consistently
poor load tracking below 325 MW. Improving the accuracy in
this region would improve the unit’s dispatch quality measure.
Although there do not appear to be any significant performance
differences attributable to either control method, it should be
noted that the pulse-type control method does use considerably
more hardware to implement. There were also problems with
some of that hardware during the test program.
Instrumentation, Controls, and Automation 6 Winter 2009
11018333
Conclusion
The decision of which method SCS should use in the future is
beyond the scope of this study, but changing to set-point control
could not be justified based on performance differences in this
study. The situation appears very analogous to the situation with
plant control systems in the mid-1980s. At that time, control
system technology was based on analog electronic hardware, but
digital control systems were becoming commercially viable. The
analog systems performed well, but they were slowly becoming
obsolete. Most control retrofits were not justified based on
improved control system performance but rather on side benefits
of the new digital technology, such as improved monitoring
capabilities and reduced maintenance effort.
In the case of dispatch technology, the pulse methods using
RTUs is equivalent to the analog control systems of the 1980s,
and the set-point method using corporate networks is equivalent
to the digital control systems. There may not be much difference
in performance of the two systems, but one is based on modern
technology and the other is based on soon-to-be-obsolete
technology. It appears that it is only a matter of time before the
set-point method over networks is the accepted standard for this
application. The more difficult challenge is to determine the most
cost-effective method of implementing such a system.
Implementing the set-point control with the ICCP provides
an additional benefit over the RTU-based system. The ICCP
enables the communication of many other parameters between
the dispatch system and the plant DCS. Although this capability
may not be useful today, it likely will be in the near future as
dispatch systems become more capable of using additional plant
information. Near real-time unit heat rate could be used in the
economic dispatch function within the dispatch system, as an
example.
For more information, contact John Sorge, 205.257.7426,
jnsorge@southernco.com, or Aaron Hussey, 704.595.2509,
ahussey@epri.com.
Survey of Commercial and Near-Commercial High-Temperature
Strain Sensors
Introduction and Background
When solid materials are subjected to stresses, they deform, and
that deformation is called strain. It is generally not possible to
measure stress directly in materials, but it is possible to measure
the strain and infer the stress level. Strain measurement is crucial
to understanding the behavior of materials, and understanding
the behavior of materials is crucial to designing successful
products, including power plants.
Power plants contain thousands of engineered products that
are subjected to significant stresses under normal and abnormal
operating conditions. The vast majority of these, such as pipes
and fittings, pressure vessels, headers, valves, and pumps, are
made of metal. Although these products were designed with the
best available technology at the time they were manufactured,
some do occasionally fail. These failures can be catastrophic and
endanger personnel and equipment and cause serious financial
losses. It is important to understand why the failures occurred
to prevent them in the future. It is also important to develop
monitoring methods to detect the problems before they become
catastrophic failures.
Many of today’s fossil-fired power plants are operating beyond
their original design lifetime. Metal failures mechanisms depend
on many things, and one important contributor for several
common mechanisms is the operating time. As plant equipment
gets older, it is more prone to failure. This is particularly true
for equipment that operates at high temperatures in the 800–
1000°F (427–538°C) range. As plant equipment ages, monitoring
becomes more important because failures are more likely.
The power generation industry has always monitored the major
pieces of equipment in its plants, but generally the monitoring
has not included material strain. Instead of directly monitoring
strain, plant operators generally monitor other operating
parameters, such as temperature, pressure, flow, and vibration.
The assumption is that if operating conditions are maintained
within proper bounds, the stress on the equipment will also be
within design limits. Although this is a reasonable approach,
its usefulness decreases when equipment is operated beyond its
designed lifetime. This approach also tends to overlook transient
events during which operating conditions may temporarily exceed
limits and cause considerable damage to equipment.
Instrumentation, Controls, and Automation 7 Winter 2009
11018333
In order to maintain high reliability in their aging fossil-
fired fleets, many power companies are looking for improved
monitoring methods for their major equipment in the plants.
One area of particular interest is monitoring strain in some of
the high-temperature, heavy metal pieces, such as boiler headers
and high-pressure piping. Measuring strain at high temperature
has always been a challenge, but there have been some technology
developments in recent years that may make the process more
accurate and easier. This brief report covers the current availability
of high-temperature strain sensors and their applicability to
monitor power plant equipment in operation at a plant site.
Strain Gauges
A sensor that is designed to measure material deformation is called
a strain gauge. There are many different types of strain gauges
available commercially, and more types are being developed.
Commercially available strain gauges include resistive gauges,
capacitance gauges, fiber-optic gauges, strain markers, and optical
image gauges. Some important characteristics of strain gauges are
cost of the gauge, cost of the measuring equipment, usability in
the field, maximum operating temperature, long-term stability or
drift, sensitivity, temperature effects, and accuracy.
Resistive Strain Gauges
Resistive strain gauges are the most common strain measurement
instrument. They can be made with wire, foils, semiconductors,
or thin films. They work on the principle that the resistance of
a material depends on its geometry and that when a strain gauge
undergoes strain, the geometry of the material changes slightly,
which causes its resistance to change. The small resistance changes
are typically detected by using a Wheatstone bridge circuit.
The wire and foil gauges are made by bonding the wire or foil
to a backing material or carrier. The wire or foil conductor is
arranged in long thin strips parallel to the expected direction
of the strain. This design increases the sensitivity of the gauge
in the parallel direction and decreases the sensitivity in the
perpendicular direction. The backing makes it easier to handle
the delicate gauge and provides electrical isolation from the part
being tested. To ensure that the strain gauge experiences the
continued on page 8
Survey of Commercial and Near-Commercial High-Temperature Strain Sensors
continued from page 7
same strain as the part being tested, the gauge assembly is firmly
bonded to the test part using adhesives or, for high-temperature
applications, spot welding. Normal adhesives cannot be used for
extended periods above 450°F (232°C), but, for short-term use
(<10 hours), temperatures can go as high as 700°F (371°C). For
higher temperatures, the gauge can be attached to a metallic shim
with a special ceramic adhesive before the shim is welded to the
test part.
Temperature Compensation
One problem with resistive strain gauges occurs when the gauge
is used at a different temperature from when it was attached to
the specimen. For instance, if a strain gauge were mounted on
the specimen at room temperature, about 80°F (27°C), but the
strain measurement were needed when the part was operating
at 350°F (177°C), the specimen would have significant thermal
expansion when its temperature increased from 80°F to 350°F
(27°C to 177°C). The strain gauge would also undergo thermal
expansion but probably not at the same rate as the specimen. The
difference in the expansion rates causes strain in the strain gauge,
which shows up as a reading on the strain instrument. This strain
reading is not a result of any stress on the specimen but is solely a
result of the thermal expansion. This false strain reading is called
thermal output.
For most uncompensated strain gauges, the thermal output will
be much larger than the strain of interest; therefore, it must be
compensated for in order to have a useful strain measurement.
Another component of thermal strain is caused by the change
in resistivity of the strain-gauge material with temperature. This
generally has a much smaller effect than the output caused by
the different expansion rates, but it still needs to be compensated
for.
There are two methods of compensating for these unwanted
thermal effects. One is to use an identical dummy strain gauge
connected to the opposite side of the Wheatstone bridge. The
dummy gauge is mounted next to the real gauge so that it is at
the same temperature as the real gauge. It must also be mounted
on the same type of material as the real gauge, but the material
must be unstressed. Usually, this would dictate a small separate
piece of material. In this way, the output from the dummy gauge
will be entirely thermal output, and, because it is on the other
Instrumentation, Controls, and Automation 8 Winter 2009
11018333
side of the bridge circuit, it will cancel the thermal output of the
real gauge. This method works well but does require two strain
gauges to make one reading. It is also important that the two
gauges be identical so that the cancellation is nearly perfect.
Another method of dealing with the thermal output is to use
self-compensating strain gauges. These are made of special alloys
in which the thermal expansion coefficient can be controlled
during the manufacturing process. The idea is to make the
thermal expansion coefficient so that the thermal output of the
gauge is zero when it is mounted on a specified material. Self-
compensating gauges are made for thermal expansion rates for
different materials. If the specimen is steel, a gauge designed for
steel must be used. Although the compensation with this method
is not quite as good as with the dummy gauge method, it is easier
to use and less expensive.
In summary, resistive gauges are subject to significant thermal
effects, which must be dealt with effectively in order to achieve a
meaningful strain measurement.
Thin-Film Resistive Gauges
The need to measure strain at high temperatures on gas turbine
engine blades has led to the development of thin-film gauges.
Thin-film gauges are made by sputter depositing very thin
layers of material directly on the surface of the test specimen.
Because the thin films are only tens of mm, they do not cause any
aerodynamic interference to the turbine blade while it is operating.
National Aeronautics and Space Administration’s (NASA’s) Lewis
Research Center has developed resistive strain gauges based on a
new alloy, palladium (13% chromium [PdCr]). The PdCr alloy
was selected as the best material for high-temperature strain
gauges by United Technologies Research Center under a NASA
contract. PdCr is oxidation resistant and stable structurally up
to 2000°F (1093°C). It also has a linear and repeatable change
in resistance with temperature. Wire strain gauges were made
first and tested up to 1472°F (800°C). Later, NASA developed
a thin-film gauge especially for use on turbine blades. The
thin-film gauge is made by sputter depositing very thin layers
of material directly on the test specimen. The first layer is an
insulating material to electrically isolate the PdCr gauge from the
continued on page 9
Survey of Commercial and Near-Commercial High-Temperature Strain Sensors
continued from page 8
base material. The PdCr gauge is then deposited on top of the
insulating material. The total thickness of the gauge is around
10 µm, which is thin enough to not cause aerodynamic problems
during operation of the turbine blades. In addition, weldable
gauges have been fabricated by making a thin-film gauge on a
weldable shim, which is then bonded to the test specimen by spot
welding.
Thin-film gauges have been made using other materials besides
PdCr, such as aluminum-nitride and other semiconductor
materials. The advantage of these semiconductor materials is that
the properties of the material, such as the gauge factor, can be
modified by altering the doping concentrations.
Capacitive Strain Gauges
Another method for measuring strain is to convert the
displacement of the specimen into a change in capacitance. The
change in capacitance can then be detected electronically. One
big advantage for capacitance strain gauges over resistive gauges
is that the capacitance gauge is not affected by temperature as
the resistive gauge is. However, the specimen is still affected by
thermal growth, so temperature compensation for that effect is
still required whenever the strain measurement is being made at a
temperature different from that at which the gauge was mounted.
This can be done by making the strain-gauge rod from the same
material as the specimen.
Capacitance strain gauges are more complex and difficult to
manufacture than resistive gauges and as a result are considerably
more expensive, typically about $1000 each. If only a few gauges
are needed, the cost may not be a major issue, but, if many gauges
are needed, it will probably be a factor.
Capacitive strain gauges that operate at temperatures up to
1500°F (816°C) are commercially available. In addition to being
unaffected by temperature, they are also very stable over time,
which allows static strain measurements to be made over long
periods of time. For high-temperature applications, the gauges
are mounted on a metal shim, which is then spot welded to the
specimen being tested.
Optical Fiber Strain Gauges
Two types of optical fiber strain gauges using Bragg grating
technology and Fabry-Perot interferometry have been developed.
It would seem logical that optical fiber strain gauges would
Instrumentation, Controls, and Automation 9 Winter 2009
11018333
be useful for high-temperature applications, but there is little
information available on such applications. EPRI funded the
development of such a strain gauge in the mid-1990s. It was tested
at the Instrumentation and Control Center, but it never made it
as a commercial product.
In a Fabry-Perot strain gauge, a cavity is formed between the
ends of two fibers. The width of the cavity is measured using
Fabry-Perot interferometry. The two fiber ends are mounted so
that the cavity width changes as the specimen is deformed. Light
travels down the fiber until it reaches the end of the fiber. At the
interface between the fiber and the air in the gap, part of the light
is reflected back up the fiber, and part is transmitted into the air
gap. On the far side of the air gap is another fiber end, which
serves as a mirror and reflects the light back across the gap and
into the fiber. This light then combines with the light reflected
by the first fiber-gap interface and travels back up the fiber to the
sensing system. The characteristics of the reflected light depend
on the cavity width, and, using white light cross-correlation
techniques, it is possible to determine cavity width.
A Bragg grating is a small section of optical fiber in which the
refractive index is altered periodically to selectively filter the light
passing through the fiber. The frequency of the filtered light
depends on the spacing of the grating. To make a strain gauge,
the fiber is attached to the specimen so that as the specimen
undergoes strain, the Bragg grating does, too. The strain in the
grating changes the spacing of the grating as well as the frequency
of the light passing through the grating.
Grid Methods
Whereas most strain sensors measure strain indirectly using
resistance or capacitance changes, grid-type sensors measure
strain directly. The basic concept is to use an identifiable grid on
the surface of the specimen, which may be naturally occurring
or artificially applied. As the part is tested, the grid is deformed
and the relative positions of the marks in the grid are measured,
which is the challenging part. For most applications, the amount
of movement is very small and optical techniques are required to
obtain the necessary accuracy. In some cases, a direct measurement
may be made using an optical comparator. Several techniques
have recently been developed using lasers and the principles of
interferometry.
continued on page 10
Survey of Commercial and Near-Commercial High-Temperature Strain Sensors
continued from page 9
Several type of grids or markers are used with this method. The
grid may be small for point-type measurements or large for full-
field measurements. It may also be 1-D or 2-D, depending on
whether the principal strain direction is known a priori. Some
of these methods that use lasers to interrogate the grid can be
used at high temperatures; however, their use in the field rather
than the laboratory may present problems. One issue is that the
measurements tend to be quite slow compared with a resistive
strain gauge, so their use for quasi-real-time monitoring might
be marginal.
One type of grid marking system is a grating of fine parallel lines
or a cross grating of orthogonal lines. A typical line spacing is
0.1 mm (0.003 in.), and a typical size might be 5.0 mm (0.196
in.) square. Such a grid could provide strain information on a
micro scale if one examined only a few lines at a time or could
provide macro-scale data if the whole grating was examined at
one time. If thousands of micro-scale readings could be made
over the entire grating, the full-field strain information could be
obtained. Automated optical measuring techniques are needed to
make the full-field type of measurement practical.
Another variation of this technique has been developed by Direct
Measurements, Inc. (DMI). Its method affixes an image to
the specimen in a similar way that the resistive strain gauge is
attached. The image is designed to be read by an image sensor and
computer to determine the strain. The image can be large or small,
depending on the needs of the application. The image can also be
laser-etched onto the part for high-temperature applications, and
work is underway to develop laser-etched weldable shims that can
be applied to a specimen in the field in the same way weldable
strain gauges are applied. The DMI gauges seem to be directed
to measuring permanent strain in materials over long periods of
time. They can also be used to measure quasi-real-time strain if
the reader can be placed over the specimen while the specimen is
in operation on a plant.
Laser Speckle Methods
A variety of strain measuring systems have been developed since
1980 using a technique called laser speckle interferometry (LSI).
The first strain gauge based on LSI was reported by Yamaguchi
in 1981. In this gauge, the surface of the specimen is illuminated
by two laser beams incident from 45° angles to the surface. The
surface of the specimen has inherent roughness, which acts as a
natural grating and reflects a speckle pattern when illuminated
Instrumentation, Controls, and Automation 10 Winter 2009
11018333
by the lasers. A 1-D photodiode array is used to detect the
reflected light intensity. Cross correlation of the undeformed and
deformed intensity patterns gives the displacement of the speckles.
The displacement measured by a single laser includes the strain
on the surface and any translation of the surface. By taking the
difference between the displacements from each laser, the strain is
obtained and the translation of the surface is eliminated.
Many improvements and extensions to this method have been
developed by taking advantage of better imaging techniques
and faster computation capabilities. As a result, the method has
been used for 2-D and real-time measurements. This technique
appears at this time to be limited to laboratory-type measurement
but may in the future be applicable in the field.
The grid methods have made many improvements in recent years
as a result of the use of low-cost lasers, improved image processing
methods, and faster computing systems. However, they still do
not appear to fit the needs of a continuous strain monitoring
system for use in the field. They are more useful for laboratory-
type applications.
Commercial Availability
A list of some key strain-gauge suppliers follows, along with a
brief description of what they provide.
Vishay Intertechnologies, Inc., www.vishay.com
Vishay provides strain-gauge products under the Micro-
Measurements brand. The company has an extensive array
of resistive strain gauges, including weldable gauges rated for
1200°F (649°C) operation.
See www.vishay.com/docs/11530/hightem.pdf. It also supplies
strain measurement systems.
Hitec Products, Inc., www.hitecprod.com
Hitec manufactures many types of strain gauges and appears
to specialize in high-temperature applications. It sells weldable
resistive and capacitance gauges rated up to 1500°F (816°C). It
also sells a PdCr weldable strain gauge, although it is not a thin-
film type. See:
• www.hitecprod.com/Pdf%20files/70_HtempweldSC.pdf
• www.hitecprod.com/Pdf%20files/70_Hitempbonded.pdf
• www.hitecprod.com/Html%20Pages/capacitive.html
• www.hitecprod.com/Pdf%20files/70_palladium.pdf
continued on page 11
Survey of Commercial and Near-Commercial High-Temperature Strain Sensors
continued from page 10

HBM, www.hbm.com
S. C. Schneider, Y. Gautam, and B. G., Zagar, “Application
HBM is a large European manufacturer of strain gauges and sells
of a Locally Operating Laser-Speckle Strain Sensor,” IEEE
a fiber-optic strain gauge using the Bragg grating principle, but it
Transactions on Instrumentation and Measurement, Vol. 52,
is not rated for high-temperature use.
No. 4, August 2003.
Geokon, www.geokon.com
“Strain-Gauge Selection: Criteria, Procedures,
Geokon sells a fiber-optic strain gauge using the Fabry-Perot
Recommendations,” Tech Note TN–505–4, Vishay Micro-
interferometer method, but it is not rated for high-temperature
Measurements, available from www.vishay.com/strain-gauges/
use. It appears to be primarily intended for monitoring bridges,
knowledge-base-list/technotes-list.
tunnels, dams, and other civil engineering structures.
“Strain-Gauge Thermal Output and Gauge Factor Variation
Kyowa Electronic Instruments Co., Ltd.,
with Temperature,” Tech Note TN–504–1, Vishay Micro-
http://www.kyowa-ei.co.jp/english/index_e.htm
Measurements, available from www.vishay.com/strain-gauges/
Kyowa is a Japanese manufacturer of strain gauges. It appears to
knowledge-base-list/technotes-list.
have a large product line but does not have any rated for high-
temperature applications. There is a helpful introduction to strain I. Yamaguchi, “A Laser Speckle Strain Gauge,” Journal of Physics
gauges on the company’s web site. E: Scientific Instrumentation, Vol. 14, 1981.
For more information, contact Cyrus Taft, 865.850.4460,
See http://www.kyowa-ei.co.jp/english/pdf/whats.pdf. cwtaft@taftengineering.com.

References

J. F. Cardenas-Garcia, M. M. Wu, and J. Hashemi, “A Review

of Strain Measurement Techniques Using the Grid Method,”
Nontraditional Methods of Sensing Stress, Strain, and Damage in
Materials and Structures, ASTM STP 1318, George F. Lucas and
David A. Stubbs, eds. ASTM, Philadelphia, 1997.
J. G. da Silva, A. A. Carvalho, and R. O. Rodriges, “High
Sensitivity Low Cost Capacitive Strain Gauge,” IMTC 2004,
Como, Italy.
J. L. Green, J. F. Emslie, and S. C. Chou, “The Application
of Laser Speckle Interferometry to Measure Strain at Elevated
Temperatures and Various Loading Rates,” MTL TR 90–23,
U.S. Army Materials Technology Laboratory, 1990.
J.-F. Lei and H. A. Will, “Thin-film thermocouples and
strain-gauge technologies for engine applications,” Sensors and
Actuators A, 65 (1998) pp. 187–193.
C. S. Lynch, “Strain Measurement,” The Measurement,
Instrumentation, and Sensors Handbook, J. Webster, ed.,
CRC Press, 1999.
W. F. Ranson, R. Vachon, G. Hovis, “Crack Initiation
Detection and Crack Growth Monitoring with DMI
Technology,” available from www.directmeasurements.com/
downloads.html.

Instrumentation, Controls, and Automation 11 Winter 2009

11018333
Fleetwide Monitoring Interest Group Web Site Instructions
Step 1: Log in to www.epri.com.
Step 2: Select EPRI Collaboration from the navigation pane.

Step 3: Select Fleetwide Monitoring Interest Group (FWMIG) from the Community Projects list.

Step 4: Read through the Terms of Use, and click Accept to access the web site.

Step 5: Adjust your pop-up blockers for the site.

continued on page 13

Instrumentation, Controls, and Automation 12 Winter 2009

11018333
Fleetwide Monitoring Interest Group Web Site Instructions
continued from page 12

Contents of the Web Site

Content 1: Overview
The opening page of the web site contains an overview including recent announcements, updated documents (a compressed list), and
recent messages posted on the Discussions tab.

Content 2: Calendar
The calendar is not used for registering for EPRI events, because www.epri.com has full capability to handle that function. However,
major events will be listed.

continued on page 14

Instrumentation, Controls, and Automation 13 Winter 2009

11018333
Fleetwide Monitoring Interest Group Web Site Instructions
continued from page 13

Content 3: Documents
The Documents tab contains folders with all previous meeting materials and documents created by the group.

To access documents, simply open the folder by either expanding in the navigation pane (left) or clicking the blue text in the right
pane. To download all files in the simplest manner, select all files in a folder, click Download, and select the Zip Download option.

Content 4: Discussions
Discussions on subjects of interest to the FWMIG are encouraged and will be monitored for content by the EPRI project manager.

For more information, contact Aaron Hussey, 704.595.2509, ahussey@epri.com.

Instrumentation, Controls, and Automation 14 Winter 2009

11018333
2010 Program 68 Overview
Utilities need to improve the capability to detect damage to plant
equipment while preserving the focus of skilled instrumentation
and controls staff on plant operations and system performance.
Additional sensors are needed to improve equipment condition
monitoring, enabling optimization of maintenance tasks. Control
systems have evolved from analog to digital, with new technology
available to improve plant performance and operational
effectiveness. EPRI’s Instrumentation, Controls, and Automation
program (Program 68) identifies, develops, and demonstrates
state-of-the-art sensing, monitoring, diagnostics, and control
system technologies that improve equipment condition assessment
and plant performance and help to accurately measure critical
plant variables.
Product Types
Products developed by this program provide guidance through
technical reports, guidelines, process specifications, web casts,
and seminars and workshops on high-priority research projects.
Program activities address the identification and transfer of new
technology and help optimize the use of existing instrumentation
and control equipment, which can cost-effectively improve plant
performance.
Technology development and demonstration projects address
critical aspects of fossil plant instrumentation and control systems,
including advanced controls, automation, improved loop tuning,
and equipment diagnostics. Applied research is conducted in
collaboration with universities, laboratories, equipment vendors,
and host utility sites. The focus includes automation of key
plant system operations to improve consistency of the startup/
shutdown process while minimizing wear and tear, increasing
plant operational efficiency through the development and
demonstration of control system improvements, and improved
tuning processes that save time and improve consistency and staff
knowledge capture.
Technology transfer projects provide Fleetwide Monitoring
Interest Group (FWMIG) meetings twice a year, which
offer open peer-to-peer information exchanges and formal
presentations by vendors on member-selected subjects. Meeting
materials, including presentations, minutes, and other related
files, are distributed to all meeting participants. The FWMIG
guides EPRI research in online monitoring, wireless, and sensor
technology.
Technology Solutions
Instrumentation, controls, and automation technology solutions
can improve plant staff knowledge and provide cost-effective
evaluation of state-of-the-art technology prior to full-scale
implementation. Some examples of technology developments and
demonstrations include the following:
• Automation of equipment and processes improves the consistency
of startups/shutdowns, helps capture expert knowledge, and
reduces unnecessary equipment damage.
• Improved control system performance leads to more responsive
plant operation, better efficiency, reduced emissions, and
reduced likelihood of damaging temperature transients.
• Multi-loop tuning methods result in significantly better
performance for control systems and lead to better, more robust
tuning of boiler control systems.
• Automation of control system tuning methods improves
consistency and enables the expertise of control engineers to be
applied on a broad scale.
• Wireless sensor networking will reduce the cost of installation of
additional sensors, enabling more effective detection of critical
equipment failure modes.
Experience gained through this research will be directly applicable
to existing plants and new plant designs, enabling more effective
application of online monitoring technology to create smarter
components. A list of 2010 technologies to be developed is shown
in Table 1 on page 16.
Transfer of Technology Solutions to the Industry
Held twice a year, FWMIG meetings offer open peer-to-peer
information exchanges and formal presentations by vendors
on member-selected subjects. Meeting materials, including
presentations, minutes, and other related files, are distributed to
all meeting participants. The FWMIG will guide EPRI projects
on centralized on-line monitoring and diagnostics technology.
A technical update, Instrumentation and Control Guideline, will
be issued annually on member-selected topics. These topics
may include instrumentation, calibration, controls, automation,
sensors, online monitoring, and wireless technology. The focus
of these reports will be on best practices in the electric utility and
other industries. As funding permits, assessments of emerging
technologies and their early adoption in power-producing facilities
will be conducted through web casts and documented in the form
of technical updates. A list of 2010 technology transfer activities
is provided in Table 2 on page 16.
continued on page 16

Instrumentation, Controls, and Automation 15 Winter 2009

11018333
2010 Program 68 Overview
continued from page 15

Table 1. Technologies to be developed in 2010

Planned Product
Product Title and Description
Completion Date Type

Multi-Loop Tuning Implementation Results: Multi-loop tuning technology has been developed and
Technical
refined within this program for two years. This product will document the results from implementing the December 31, 2010
report
method on a complex, multivariable control system, such as that found in a typical coal-fired boiler.

Barriers to Implementing Advanced Controls: Modern control systems include technology for advancing

control system capabilities, including automated tuning parameter derivation and multivariable control.  Technical
December 31, 2010
Although the technology is ready, some key barriers exist to cost-beneficial implementation. This product resource
will identify and document key barriers and the path to overcome them.

Asset Fault Signature (AFS) Database: During 2009, a working prototype of EPRI’s AFS Database has
been released with a limited content of fault signatures sufficient to demonstrate and test functionality. In
2010, EPRI will support the prototype evaluation of the AFS Database through web training. Functional-
ity enhancements suggested by end users will be identified and implemented. Significant effort will be
applied in 2010 toward populating the AFS Database with additional design cases using available EPRI December 31, 2010 Software
sources on fossil plant component failure modes and effects. The final result, following the 2010 work,
will be a production version of the AFS Database ready for use by the industry. This product will be a
supporting database to EPRI’s Diagnostic Advisor tool that employs a case-based reasoning process for
equipment fault diagnostics.

Using Control Systems for Operational Flexibility: With a changing electricity production and
demand landscape, some baseloaded plants today might become load-following plants tomorrow. 
Technical
Many challenges exist, some of which will require the use of digital control system technology for different December 31, 2010
update
operational profiles. This study will document the current state-of-the-art applications of controls for this
purpose as well as the barriers that exist.

Table 2. Technology transfer activities for 2010

Planned Product
Product Title and Description
Completion Date Type

FWMIG Meetings: The FWMIG meets twice annually (typically in May and October) to discuss chal- Workshop,
lenges and solutions related to the implementation of on-line monitoring technology. Topics include thermal December 31, 1010 training, or
performance monitoring, equipment condition assessment, data integration, and technology gaps. conference

Instrumentation and Control Guideline 2010 Topical Update: Instrumentation and Control Guideline
will be updated annually with at least one new topic as voted on by the program advisory committee. Technical
December, 31, 2010
The topic will be reviewed, and potential and proven industrial applications will be identified and docu- update
mented.

For more information, contact Aaron Hussey, 704.595.2509, ahussey@epri.com.

Instrumentation, Controls, and Automation 16 Winter 2009

11018333
Summary of the Fall 2009 EPRI Fleetwide Monitoring Interest Group
Meeting
EPRI’s Fleetwide Monitoring Interest Group (FWMIG) Meeting • Scientech
was held from Tuesday, October 13, through Thursday, October • Wi-Fi Sensors
15, 2009, in The Woodlands, Texas. The meeting was structured • Instep
with the following main features: • ESRG
• Tuesday: steering committee meeting, new member session, • General Physics Corp.
plenary session with keynotes, industry project updates, and
The tour by Entergy was a success, with discussions held on plant-
panel discussion on wireless
center communications, startup monitoring, operations support,
• Tuesday evening: reception and vendor fair
and many other topics.
• Wednesday morning: presentation sessions—advanced
modeling techniques, nuclear monitoring, diagnostics and On Thursday morning, an open round table discussion produced
prognostics, and sensors and wireless technology the following ranked topics that were discussed in order of
• Wednesday afternoon: a tour of the Entergy’s Performance ranking:
Monitoring and Diagnostics Center hosted by Gary Barnes 1. Communication with plants
• Thursday morning: open discussion in a round table format 2. How to get started
3. Modeling practices: general
The October 2009 EPRI FWMIG meeting featured two keynote
4. Modeling practices: startup/shutdown
speeches: “What has Fleetwide Monitoring Done for Entergy
5. Other types of data/information
Fossil?” by Etienne Senac, vice president of Fossil Operations for
6. Thinking outside the box
Entergy Corp., and “Innovation” by Clinton Carter, manager of
7. What’s next
the Power Optimization Center for Luminant.
For more information, contact Aaron Hussey, 704.595.2509,
A range of technologies was displayed on Tuesday evening, with ahussey@epri.com.
the following vendors represented:
• Black & Veatch Corp.
• SmartSignal Corp.
• PAS, Inc.

Upcoming Events
Event Name Location Date(s)

Winter Program 68 Advisory Meeting Orlando, Florida March 9, 2010

Spring Fleetwide Monitoring Interest Group (FWMIG) Meeting Charlotte, North Carolina May 4–6, 2010

20th Joint International Society of Automation Power Industry Division/EPRI Summerlin, Nevada June 7–11, 2010
Instrumentation and Controls Conference

Fall FWMIG Meeting Raleigh, North Carolina, or October 12–14, 2010

Dallas, Texas

For more EPRI Events, visit the Events Calendar at www.epri.com.

For more information on any of these events, contact Judy Brown, 704.595.2694, jubrown@epri.com.

Instrumentation, Controls, and Automation 17 Winter 2009

11018333
P68 Product List
A recently published report, Descriptions of Past Research (1020371), describes past EPRI reports, training materials, and software
associated with Program 68, Instrumentation, Controls, and Automation. It is intended to be used as a reference guide to allow
members to easily search for existing products relevant to specific topics of interest. This report contains product summaries for
more than 100 past products, arranged in seven technical categories. The products summarized in this report were released from
1987 through deliverable year 2009. All products listed in this document are available for download or ordering from the EPRI web
site, www.epri.com. EPRI members are encouraged to refer to the document frequently to assess what reports and software tools are
already available to assist in addressing their organization’s instrumentation, controls, and automation needs.
Controls
Report Title Date Report #
Model Predictive Control Demonstration Model Indentification Testing and Simulation Results 03/31/2009 1015711
Advanced Control Technology Update 03/30/2008 1014925
Instrumentation and Control Technology Assessment 02/21/2007 1014237
Investigation of Adaptive Control Techniques for Improved Fuel Flexibility 03/21/2007 1012260
Power Plant Control System Troubleshooting Short Course Notes 03/31/2006 1010262
Advanced Control Demonstration on a Combined Cycle Plant 03/31/2006 1010261
Control System Retrofit Guidelines Update Review of Original Report and Recommendations for Updating 12/23/2005 1010263
Power Plant Control System Troubleshooting Course: Progress Report and Outline 03/30/2005 1004817
Quantifying the Value of Control System Performance Improvements 12/22/2004 1009844
Boiler/Turbine Model Identification Procedure 12/20/2004 1010545
Advanced Control Demonstration on Combined Cycle Plant: Progress Report 12/20/2004 1010543
Advanced Control Demonstration Throttle Pressure and Megawatt Control Studies 03/25/2004 1003738
Advanced Pulverizer Control: Design and Testbed Implementation 03/22/2004 1004423
Advanced Pulverizer Control: 2002 Progress Report 05/19/2003 1008161
Advanced Control Demonstrations 2002 Progress Report 03/28/2003 1004424
Active Burner Balancing Control Guidelines 02/05/2001 1004012
Guidelines for Intelligent Sootblowing Control 12/15/2000 1000410
Active Burner Balancing Technology Review: Interim Progress Report 11/16/2000 1000342
Demonstration of Advanced Control Techniques on Fossil Power Plants 12/05/2000 1001069
Robust Controller Design for Simultaneous Control of Throttle Pressure and Megawatt Output in a Power Plant Unit 12/15/1999 TR-111629
Application Guidelines for Advanced Control in Fossil Plants 12/15/1999 TR-114339
Demonstration of an Advanced Sootblowing Control System Case Study: Application of Intelligent Sootblowing
at PowerGen’s Kingsnorth Power Station 11/15/1999 TR-114420
Proceedings Workshop on Intelligent Sootblowing Applications 12/31/1998 TR-111631
Low Load Low Air Flow Optimum Control Applications 11/30/1998 TR-111541
Survey of Instrumentation and Control Practices in the Process Industries for Application to the Power Utilities 11/30/1998 TR-112230
Advanced Control for Fossil Power Plants 10/15/1998 TR-111674
Guidelines for Inter Control Center Communications Protocol (ICCP) Implementation Plant Controls to Dispatch Computer 08/31/1999 TR-113652
Guidelines for the Selection and Application of Power Plant Control Valves: Revision 1 08/01/1997 TR-102051-R1

Online Monitoring
Experience-Derived Fault Signature Database Functional Specification 12/23/2008 1015713
Program on Technology Innovation: On-Line Monitoring Data Classification for Improved Modeling Effectiveness 12/23/2008 1016189
Program on Technology Innovation: Improved Probability of Failure Analysis Using On-Line Equipment Condition Monitoring Data 01/31/2008 1016173
Fleetwide Monitoring for Equipment Condition Assessment 03/30/2006 1010266
Equipment Condition Assessment Modeling Guidelines 12/23/2005 1010038
On-Line Monitoring for Equipment Condition Assessment Model Evaluations and Alarm Settings 12/21/2005 1010466
Application of On-Line Monitoring Techniques to Equipment Condition Assessment 12/20/2005 1010034
Equipment Condition Assessment: Volume 2 Technology Evaluation and Integration 12/22/2004 1009601
On-Line Monitoring for Equipment Condition Assessment: Application at Progress Energy 12/20/2004 1008416
Equipment Condition Assessment: Application of On-Line Monitoring Technology 12/22/2004 1003695
On-Line Monitoring of Instrument Channel Performance: Volume 1: Guidelines for Model Development and Implementation 12/21/2004 1003361

Automation
Automation of Fossil Plant Startup Shutdown Instrumentation Controls Technology Assessment 03/29/2007 1015710
Demonstration of Automation on a Combined-Cycle Plant 03/29/2007 1013344
Automation in Power Plants and Wireless Technology Assessments 12/21/2005 1010468
Combind-Cycle Automation Demonstration Progress Report 12/21/2005 1011959
Roxboro Integrated Automation Project 12/31/1996 TR-106803

Instrumentation, Controls, and Automation 18 Winter 2009

11018333
P68 Product List
continued from page 18

Sensors
Report Title Date Report #
Program on Technology Innovation Nanotechnology Enabled Ultrasensitive Gas Sensors Prototype Development 12/23/2008 1016174
Slag Deposition Monitoring Using Strain Gage Technology 12/14/2006 1012261
Demonstration of Wear and Tear Sensors for Measurement of Damage 03/30/2006 1010462
Temperature Sensor Evaluation 06/01/1996 TR-106453
In-Situ Combustion NOx Analyzer Sensor 12/21/2005 1010465
Demonstration of Advanced Boiler Instrumentation Technologies 03/31/2005 1008144
Demonstration of Wear and Tear Sensors 2004 Progress Report 03/31/2005 1009845
Application of Strain Gage Technology for Slag Deposition Monitoring 03/29/2005 1004821
Measurement of Slag Deposition Using Strain Gage Technology Evaluation of TVA Cumberland Plant 08/18/2004 1003742
Feasibility of Wear and Tear Sensors for Flexible Plant Operations 12/09/2003 1003732
Evaluation of Advanced Combustion Monitoring Sensors 11/25/2002 1004427
Sensors for Furnace Ash Deposition Measurement on Boiler Tubes Technology Review 12/01/2000 1000409
CO Monitoring Instrumentation and Applications Technology Assessment 11/15/2000 1000343
At the Burner Combustion Measurement Case Study Report: Demonstrations of Forney’s OptiFlame and
MK Engineering’s MPV 1 Combustion Sensors 12/15/1999 TR-114719
NIST’s Ultrasonic Technology Assessment Program to Improve Flow Measurement 03/31/1998 TR-111311
Enhancement of the Accuracy of Steam Temperature Measurement by Eskom 03/31/1998 TR-110712
Fiber-Optic Fabry Perot High Temperature Strain Measurement System Feasibility Study 08/01/1997 TR-107212
Power Plant Performance Monitoring and Improvement, Volume 4: Boiler Optimization 12/23/1987 CS-EL-4415-V4

Tuning
Multi-Loop Tuning 12/23/2008 1015712
Automated Control System Tuning Demonstration 03/30/2007 1012254
Automated Tuning Software Evaluation Technical Approach 12/20/2004 1010544
Power Plant Control System Tuning Short Course Notes 03/29/2004 1003740
Review of State of the Art PID Controller Tuning Software 08/26/2004 1008040
Control System Tuning Assessment Guidelines 12/18/2002 1004425
Automated Control System Tuning Issues, Available Solutions and Potential for Improvement 12/21/2001 1004067
Power Plant Control System Tuning 09/01/1999 TE-113653
Tuning Guidelines for Utility Fossil Plant Process Control Volume 2 01/18/1995 TR-102052-V2
Tuning Guidelines for Utility Fossil Plant Process Control Volume 1 12/27/1992 TR-102052-V1
Tuning Guidelines for Utility Fossil Plant Process Control Volume 3 12/27/1992 TR-102052-V3
Tuning Guidelines for Utility Fossil Plant Process Control Volume 4 12/27/1992 TR-102052-V4

Operational Flexibility
Demonstration of Wear and Tear Sensors 2004 Progress Report 03/31/2005 1009845
Case Studies of Enhanced I&C Systems for Improved Operational Flexibility: 2004 Progress Report 03/31/2005 1009907
Proceedings EPRI Workshop on Improved Operational Flexibility: Making the Most of Generating Assets 07/27/2004 1008142
Development of I&C Stategies for Plant Flexible Operations 03/12/2004 1008046
Feasibility of Wear and Tear Sensors for Flexible Plant Operations 12/09/2003 1003732
Revenues from Ancilliary Services and the Value of Operational Flexibility 12/02/2002 1004413
Enhanced I&C for Improved Plant Operational Flexibility: Progress Report 12/18/2001 1004068
Enhanced I&C Meeting Proceedings 12/18/2001 1006647

Wireless Technology
Demonstration of Wireless Motes for Fossil Plant Monitoring 03/31/2009 1015714
Program on Technology Innovation: Wireless Mesh Sensor Networks for Fossil Plant Monitoring 03/31/2009 1016188
Automation in Power Plants and Wireless Technology Assessments 12/21/2005 1010468
Demonstartion of Wireless Technology for Equipment Condition Assessment: Application at TXU Comanche Peak
Steam Electric Station 11/29/2005 1011826
Requirements for Application of Wireless Technology in the Power Industry 05/17/2005 1011960
Radio Frequency Identification (RFID) Technology Trends and Power Plant Applications 12/30/2004 1003733
Wireless Technology Power Plant Applications 12/18/2003 1004905
On Line Predictive Condition Monitoring System for Coal Pulverizers Application of Wireless Technology 11/14/2003 1004902
Wireless Sensor Application Survey in Power Plants 03/13/2003 1004428

For more information, contact Yolimar McCombs, 704.595.2671, ymccombs@epri.com.

Instrumentation, Controls, and Automation 19 Winter 2009

11018333
 The Electric Power Research Institute, Inc.
Contacts (EPRI, www.epri.com) conducts research and development
relating to the generation, delivery and use of electricity
John Sorge
for the benefit of the public. An independent, nonprofit
Research Engineer, Program 68 Chair
organization, EPRI brings together its scientists and
Southern Company Services, Inc.
engineers as well as experts from academia and industry
205.257.7426
to help address challenges in electricity, including
jnsorge@southernco.com
reliability, efficiency, health, safety and the environment.
Aaron Hussey EPRI also provides technology, policy and economic
Project Manager analyses to drive long-range research and development
Instrumentation, Controls, and Automation planning, and supports research in emerging technologies.
704.595.2509 EPRI’s members represent more than 90 percent of the
ahussey@epri.com electricity generated and delivered in the United States,

Yolimar McCombs and international participation extends to 40 countries.

Student EPRI’s principal offices and laboratories are located in

Instrumentation, Controls, and Automation Palo Alto, Calif.; Charlotte, N.C.; Knoxville, Tenn.; and

704.595.2671 Lenox, Mass.

ymccombs@epri.com Together...Shaping the Future of Electricity

Judy Brown
Senior Administrative Assistant
Fossil Operations and Maintenance
704.595.2694
jubrown@epri.com
Steve Hesler
Program Manager
Fossil Operations and Maintenance
704.595.2680
shesler@epri.com

1020373 Winter 2009

Electric Power Research Institute

3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
© 2009 Electric Power Research Institute (EPRI), Inc. All rights reserved. Electric Power Research Institute, EPRI, and Together . . . Shaping the Future of Electricity are
registered service marks of the Electric Power Research Institute, Inc.
11018333