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185 records · Page 11

Drones for Decommissioning

The U.S. Nuclear Regulatory Commission has responsibility for regulating the safe decommissioning of facilities and sites to meet the License Termination Rule in 10 Code of Federal Regulations (CFR) Part 20, Standards for Protection Against Radiation, Subpart E “Radiological Criteria for License Termination.” Decommissioning is performed in accordance with 10 CFR Part 50, Domestic Licensing of Production and Utilization Facilities, as part of license termination (§50.82) and release of the facility or site for unrestricted use (§50.83). The guidance currently demonstrates the minimum requirements and necessary conditions for conducting radiological surveys by a person carrying a radiation detector(s). The Pacific Northwest National Laboratory (PNNL) evaluated the use of an unoccupied aerial vehicle (UAV) to conduct radiological surveys that could be used in decommissioning to potentially reduce time, cost, and worker safety compared to current survey methods. The objective of this project was to evaluate the performance and limitations of a UAV to support a decommissioning radiological survey and compare it to a radiological survey conducted by a human. The primary research questions of interest evaluated were: 1. Did observed UAV paths differ from human paths and, if so, how much? 2. Did survey path deviation affect survey results and, if so, how? 3. Were radiological measurements from human and UAV surveys significantly different? To answer these research questions, an experimental field was set up at PNNL’s 3440 test track, and it included radiological sources commonly surveyed during decommissioning: cobalt-60 (Co-60), cesium-137 (Cs-137), and americium-241 (Am-241). Nine check sources (three each of Am-241, Cs-137, and Co-60) with activities ranging from 3.54 µCi to 39.34 µCi were set over a path that also included an area for measuring background radiation. An Aurelia X6 UAV coupled with a GPS and lidar unit was used to conduct the radiological surveys. UAV and human surveys were conducted using two different NaI(Tl) scintillation radiation detectors (2 in. × 2 in. Ludlum, Inc. and 2 in. × 0.04 in. Alpha Spectra, Inc.) at a travel velocity of approximately 0.2 m/s at a low (15–40 cm median altitude) or high (87–105 cm median altitude) survey altitude. Since the survey velocity and altitude parameters were atypical for normal UAV operations, testing was done prior to conducting the radiological surveys to establish airworthiness, evaluate the navigation system, and establish flight control. Human and UAV surveys were paired according to the detector type and altitude regime to compare the survey data. The results of this proof-of-concept research determined that the UAV and human surveys followed similar survey paths and detected the radiological sources with no significant statistical difference (in 33 out of 36 surveys). However, further research is needed prior to deploying UAVs for decommissioning surveys.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗

A combined electron beam/optical lithography process step for the fabrication of sub-half-micron-gate-length MMIC chips

Advanced radar and communication systems rely heavily on state-of-the-art microelectronics. Systems such as the phased-array radar require many transmit/receive (T/R) modules which are made up of many millimeter wave - microwave integrated circuits (MMIC's). The heart of a MMIC chip is the Gallium Arsenide (GaAs) field-effect transistor (FET). The transistor gate length is the critical feature that determines the operating frequency of the radar system. A smaller gate length will typically result in a higher frequency. In order to make a phased array radar system economically feasible, manufacturers must be capable of producing very large quantities of small-gate-length MMIC chips at a relatively low cost per chip. This requires the processing of a large number of wafers with a large number of chips per wafer, minimum processing time, and a very high chip yield. One of the bottlenecks in the fabrication of MIMIC chips is the transistor gate definition. The definition of sub-half-micron gates for GaAs-based field-effect transistors is generally performed by direct-write electron beam lithography (EBL). Because of the throughput limitations of EBL, the gate-layer fabrication is conventionally divided into two lithographic processes where EBL is used to generate the gate fingers and optical lithography is used to generate the large-area gate pads and interconnects. As a result, two complete sequences of resist application, exposure, development, metallization and lift-off are required for the entire gate structure. We have baselined a hybrid process, referred to as EBOL (electron beam/optical lithography), in which a single application of a multi-level resist is used for both exposures. The entire gate structure, (gate fingers, interconnects and pads), is then formed with a single metallization and lift-off process. The EBOL process thus retains the advantages of the high-resolution E-beam lithography and the high throughput of optical lithography while essentially eliminating an entire lithography/metallization/lift-off process sequence. This technique has been proven to be reliable for both trapezoidal and mushroom gates and has been successfully applied to metal-semiconductor and high-electron-mobility field-effect transistor (MESFET and HEMT) wafers containing devices with gate lengths down to 0.10 micron and 75 x 75 micron gate pads. The yields and throughput of these wafers have been very high with no loss in device performance. We will discuss the entire EBOL process technology including the multilayer resist structure, exposure conditions, process sensitivities, metal edge definition, device results, comparison to the standard gate-layer process, and its suitability for manufacturing.

Sewell, James S.↗

Minimum Climb to Cruise Noise Trajectories Modeled for the High Speed Civil Transport

The proposed U.S. High Speed Civil Transport (HSCT) will revolutionize commercial air travel by providing economical supersonic passenger service to destinations worldwide. Unlike the high-bypass turbofan engines that propel today's subsonic airliners, HSCT engines will have much higher jet exhaust speeds. Jet noise, caused by the turbulent mixing of high-speed exhaust with the surrounding air, poses a significant challenge for HSCT engine designers. To resolve this challenge, engineers have designed advanced mixer rejector nozzles that reduce HSCT jet noise to airport noise certification levels by entraining and mixing large quantities of ambient air with the engines' jet streams. Although this works well during the first several minutes of flight, far away from the airport, as the HSCT gains speed and climbs, poor ejector inlet recovery and ejector ram drag contribute to poor thrust, making it advantageous to turn off the ejector. Doing so prematurely, however, can cause unacceptable noise levels to propagate to the ground, even when the aircraft is many miles from the airport. This situation lends itself ideally to optimization, where the aircraft trajectory, throttle setting, and ejector setting can be varied (subject to practical aircraft constraints) to minimize the noise propagated to the ground. A method was developed at the NASA Lewis Research Center that employs a variation of the classic energy state approximation: a trajectory analysis technique historically used to minimize climb time or fuel burned in many aircraft problems. To minimize the noise on the ground at any given throttle setting, high aircraft altitudes are desirable; but the HSCT may either climb quickly to high altitudes using a high, noisy throttle setting or climb more slowly at a lower, quieter throttle setting. An optimizer has been programmed into NASA's existing aircraft and noise analysis codes to balance these options by dynamically choosing the best altitude-velocity path and throttle setting history. The noise level standard, or metric, used in the optimizer should be one that accurately reflects the subjective annoyance levels of ground-based observers under the flight path. A variety of noise metrics are available, many of which are practical for airport-vicinity noise certification. Unlike airport noise, however, the HSCT's climb noise will be characterized by relatively low noise levels, long durations, and low-frequency spectra. The noise metrics used in these calculations are based on the recommendations of researchers at the NASA Langley Research Center, who have correlated the flyover noise annoyance levels of actual laboratory subjects with a variety of measurements. Analysis of data from this optimizer has shown that significant reductions in noise may be obtained with trajectory optimization. And since throttling operations are performed in the subsonic portion of the climb path (where thrust is plentiful), only small penalties in HSCT range or fuel performance occur.

Berton, Jeffrey J.↗

Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer

GE Research and its partner Prolec GE have designed, built and deployed in the field the world’s first flexible power transformer. The flexible power transformer is a transmission class 3-phase autotransformer configurable in impedance and in voltage which allows it to serve as a universal spare for multiple units in a given fleet. However, the key innovation in this new concept is the online adjustable leakage impedance which allows the transformer to change its impedance without interrupting the transmission line operation. The flexible power transformer can be designed with up to three low voltage transmission class ratings and up to 12 impedance values changeable both online and offline. This report provides an overview of the design, manufacturing, testing, and commissioning of the 165kV, 60MVA prototype built including the results of the field performance validation tests. The prototype was specified in collaboration with Cooperative Energy, the utility host. It was designed and tested in the factory according to IEEE standard C57.12.00 and followed all protocols for transportation, installation, and commissioning of a power transformer. In addition to the prototype, a flexible protection system capable of automatically adjusting its settings upon the transformer impedance was also developed and deployed in the for testing and validation. On September 3, 2021 the prototype was energized in Cooperative Energy’s substation in Columbia, Mississippi to become the world’s first flexible power transformer in operation. Its performances and impact on the grid operation were demonstrated through different field tests. Results obtained confirm that the impedance of the flexible transformer can be varied under load through its full range, from 4.3% to 9.3%, without adverse impacts on the line operation, the protection system, the transformer stability and health condition. Results also proved that the flexible transformer is very effective in controlling power transfer through the line or load sharing between units operating in parallel. Indeed, it was proven that higher impedances decrease the thruput power of the transformer while lower impedances increase it. Up to 26MW was controllable on a line loading of 45MVA. It was also possible to demonstrate that the variation of the transformer impedance has no effect on the circulating current between units in parallel, except a minor transient during the impedance change. It was also proven that the flexible protection relay can update its protection settings automatically when the impedance change was detected. The prototype has operated continuously for more than 12 months now with a peak load exceeding 50MVA corresponding to >80% of its ONAN power rating. No alarm, trip or sign of failure has been reported by the utility. In addition to the development and deployment of the flexible transformer prototype, investigations were carried out on new nanodielectric fluids to replace the mineral oil used in power transformers with the goal of reducing their footprint and weight. The key parameters that were targeted for improvement included the breakdown voltage to reduce clearances between windings and tank hence the footprint; viscosity and thermal conductivity to increase the cooling efficiency and therefore to reduce the winding material. Several nanodielectric mixtures with mineral oil including with alumina (Al2O3), titania (TiO2) and Borum Nitrate (BN) with different surfactants have been analyzed and tested. Unfortunately, despite encouraging results no nanofluid candidate has been found viable to replace mineral oil. With the formulations tested, breakdown voltages are generally similar to mineral oil at lower particle contents and worse at higher particle contents. Viscosity appreciably increased at particles concertation over 2 wt% and thermal conductivity increased slightly at 5wt% and appears to be 10-15% higher at 10 wt% particle content. It is recommended to continue investigations to find solutions that can help increase the power density of future flexible power transformers. Flexible power transformers can significantly help the future power grid by providing more flexibility and resiliency. Indeed, by providing voltage and impedance flexibility, flexible power transformers reduce the need for multiple spares, hence inventory costs for utilities. With their online controllable impedance, they can provide support to the grid and help manage short-circuit currents, power flow, line congestion, and grid stability which will become more important with higher penetrations of intermittent renewable resources. During the field validation tests, it was demonstrated that up to 26MW was controllable on a line loading of 45MVA when the transformer impedance was varied from its minimum to its maximum range. Also, with the impedance range, the short-circuit currents could be reduced by up to 38% at the load side of the transformer. With its controllable impedance, flexible transformers can be used in future strategies of grid resilience to help better prepare the grid to face forecasted severe events including storms, heat waves and contingencies. The flexible power transformers can also find role in other applications including high voltage transmission cables such as offshore wind farms where solutions for energizing the cables and managing the reactive power are of critical importance. The designed flexible power transformer is now fully validated and ready for commercialization. Further analysis on the benefits of flexible power transformers for grid stability and short-circuit management including current limiting capability, reclosure and line restoration, control of inrush current, sizing of flexible AC components (FACTS) would help its rapid adoption by the industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗