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DOE OSTI2023

Integration of a new Cryogenic Liquefier into the IB-1 Cryogenic Test Facility

aThe increase over the last years of the testing activities related to superconducting quantum materials, SRF cavities for the PIP-II and the LCLS-II projects, as well as superconducting magnets for the HL-LHC project and Fusion research activities, has required the addition of a new Helium cryogenic plant into the existing IB-1 Industrial Cryogenic Test Facility. The new cryogenic plant is composed of a cryogenic liquefier (Cold Box) able to provide up to 340 L/h, a 4kL Dewar and two Mycom compressors providing up to 120 g/s. AL-AT (Air Liquide Advanced Technologies) has taken part of this project by designing and manufacturing the cryogenic liquefier. This new cryogenic plant is connected through a cryogenic distribution system to a 10 kL Dewar, which is part of the existing cryogenic test facility, itself composed of another Cold Box and a Sullair compressor. The new cryogenic plant has two main operating modes: one allows to transfer liquid helium at 1.7 bar between the two Dewars, the other allows to transfer supercritical Helium at 2 bar or more between the new Cold Box and the 10 kL Dewar. The entire industrial cryogenic facility is handled by a common Inventory Control System, composed of three regulatory valves, and 9 tanks giving a total buffer volume of more than 1000 m3. This paper presents the technical features of the new Helium cryogenic plant, as well as the main results of the liquefier commissioning phase and details of the helium transfer between the two dewars, making the connection between the cryogenic plants at the IB-1 Industrial Cryogenic Test Facility.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2020

Business Case Analysis for Digital Safety-Related Instrumentation & Control System Modernizations

The commercial nuclear sector faces unprecedented financial challenges driven by low natural gas prices and subsidized renewables in a marketplace that does not reward carbon-free baseload capacity. These circumstances, along with increasingly antiquated labor-centric operating models and analog technology, have forced the premature closure of multiple nuclear facilities and placed a much larger population of nuclear power stations at risk. Nuclear plant economic survival in current and forecasted market conditions requires an efficient and technology-centric operating model that harvests the native efficiencies of advanced technology. This is analogous to transformations in nearly every other industry. In light of previous industry experience in modernizing safety Instrumentation and Controls (I&C) systems, nuclear utilities are reluctant to pursue these upgrades due to uncertainty in licensing and cost.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

NETL Well Integrity Workshop: Identifying Well Integrity Research Needs for Subsurface Energy Infrastructure

Wells are a critical component of subsurface energy infrastructure. Ensuring the integrity of wells as engineered pathways for the safe extraction, injection, and storage of fluids in the subsurface is key to maximizing the effectiveness and resilience of that infrastructure. Addressing well integrity issues in a technically robust manner that promotes environmental sustainability and social equity is also an important focus of the United States (U.S.) Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management. Industry best practices, regulatory standards, modern monitoring data acquisition and control systems, and decades of research and development have dramatically improved the performance and reliability of wells for hydrocarbon extraction and underground injection in the oil and gas industry. Yet, important innovation is required to improve and ensure well integrity performance in engineered geologic systems where operational environments (fluid composition, temperature, pressure, and/or stress conditions) and long functional life cycles of well systems present unique challenges. Additionally, work is needed to understand and manage the long-term integrity and risks associated with legacy wells—especially those located adjacent to and presenting hazards for new subsurface activity.

02 PETROLEUM↗

DOE OSTI2021

Primary Frequency Control Using Motor Drives for Short Term Grid Disturbances

Industrial motor systems make up a quarter of all electric sales in the United States. Variable speed drives (VSDs) can provide energy efficiency savings to the customer by regulating motor speed based on specific and varying needs. In addition to the benefits provided to the customer, VSDs can provide support to the grid through ancillary services. The Center for Ultra-Wide-Area Resilient Electric Energy Transmission Networks (CURENT) developed a power electronics converter-based grid emulator to allow testing of various power system architectures and demonstration of key technologies in monitoring, control, actuation, and visualization. This paper proposes using an active front-end VSD's connected motor load to provide frequency regulation to a large scale power grid. Each part of the emulator is described including motor and power electronics model and control. The proposed frequency regulation is implemented in VSDs and modeled in both a transmission system in EMTDC/PSCAD and verified on CURENT's hardware testbed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

CPS Testbed Architectures for WAMPAC using Industrial Substation and Control Center Platforms and Attack-Defense Evaluation

Advanced persistent threats and cyberattacks can impact wide-area monitoring, protection, and control (WAMPAC) system operation. Many cyber-physical system (CPS) testbeds have been developed for attack-defense experimentation and attack-resiliency tools evaluation for WAMPAC, but they are limited to a simulation-and-emulation based environment. This paper presents a quasi-realistic CPS attack-defense testbed-based framework for WAMPAC applications using the industrial substation and control center platforms such as eTerra integrated with the hardware-in-the-loop CPS smart grid testbed available at Iowa State University. The proposed framework includes various combinations of industry-grade substation and control center platforms, communication topologies, real-time digital simulators, and a novel cyber-physical distributed intrusion-and-anomaly detection system (D-IADS) for WAMPAC applications. The D-IADS includes a master at the control center and geographically distributed sensor devices at each substation. Each D-IADS sensor deployed at a substation or control center network monitors ingress and egress traffic, detect intrusions, and dispatch alerts to the D-IADS master. The D-IADS master centrally monitors and analyze the alerts and controls D-IADS sensors. We considered an EMP60 synthetic CPS grid as a case study to demonstrate the framework and proposed D-IADS for WAMPAC applications against cyberattack vectors such as Man-in-the-Middle DNP3 attack, denial-of-service, and data-integrity attacks.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

2020 Component Innovation Awardee: Windurance LLC

Currently, there is no wind system power-conversion component available to wind turbine OEMs that is certified to applicable standards for use in the U.S. distributed wind energy market. Off-the-shelf industrial drives have features that are not needed by distributed wind OEMs and lack other features that would be valuable for the operation and control of wind turbine generating systems. In addition to adding costs for OEMs, these industrial drives increase uncertainty and risk for project developers and prospective owners. All of this presents barriers and increases costs for the development of distributed wind in the United States. With funding from CIP, Windurance plans to develop an industry-specific power-conversion component that will offer application-specific features at lower cost for distributed wind OEMs.

CIP↗

DOE OSTI2025

Security Assessment of an LBP16-Protocol-Based Computer Numerical Control Machine

Subtractive manufacturing systems, specifically, computer numerical control machines, have revolutionized the manufacturing industry. Computer numerical control machining is the preferred method for producing finished parts due to its efficiency, speed and suitability for high-volume production. Securing computer numerical control machines is a priority. Compromises or disruptions of these machines can result in significant downtime, loss of productivity and financial loss. This study examines the vulnerabilities and risks associated with computer numerical control machines, in particular, systems utilizing the LBP16 protocol for controller-machine communications. The study reveals that an adversary can execute cyber-physical attacks such as sabotage and denial of service. The potential security threats emphasize the importance of implementing robust security measures to mitigate the cyber risks to computer numerical control machines.

Forihat, Yahya [Virginia Commonwealth University, ↗

DOE OSTI2025

POWER ELECTRONICS GRID TIED SYSTEM FINAL REPORT

Across the country, electric utilities are grappling with the persistent hurdles of integrating Distributed Energy Resources (DERs). Managing these assets safely and effectively is a complex endeavor, complicated by varying ownership structures, management philosophies, and the diversity of the technologies themselves. Consequently, the industry has seen a proliferation of bespoke system designs, control strategies, and communication frameworks—forcing utilities to spend significant time and resources developing one-off integration solutions. This project addressed these integration hurdles through a scalable demonstration of intelligent devices designed to coordinate and control diverse resources in low-voltage applications. This concept minimized the need for complex integration by transforming the separate DERs into a dispatchable virtual power plant (VPP) with integrated resiliency functions (called a Node). By collaborating with a utility partner, the project focused on developing rapidly implementable use cases that bridged the gap between theoretical control and real-world deployment

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

The Role of Coupled Feedbacks in the Decadal Variability of the Southern Hemisphere Eddy-Driven Jet

The Southern Hemisphere summertime eddy-driven jet and storm tracks have shifted poleward over the recent few decades. In previous studies, explanations have mainly stressed the influence of external forcing in driving this trend. Here we examine the role of internal tropical SST variability in controlling the austral summer jet’s poleward migration, with a focus on interdecadal time scales. The role of external forcing and internal variability are isolated by using a hierarchy of Community Earth System Model version 1 (CESM1) simulations, including the pre-industrial control, large ensemble, and pacemaker runs. Model simulations suggest that in the early twenty-first century, both external forcing and internal tropical Pacific SST variability are important in driving a positive southern annular mode (SAM) phase and a poleward migration of the eddy-driven jet. Additionally, Tropical Pacific SST variability, associated with the negative phase of the interdecadal Pacific oscillation (IPO), acts to shift the jet poleward over the southern Indian and southwestern Pacific Oceans and intensify the jet in the southeastern Pacific basin, while external forcing drives a significant poleward jet shift in the South Atlantic basin. In response to both external forcing and decadal Pacific SST variability, the transient eddy momentum flux convergence belt in the middle latitudes experiences a poleward migration due to the enhanced meridional temperature gradient, leading to a zonally symmetric southward migration of the eddy-driven jet. This mechanism distinguishes the influence of the IPO on the midlatitude circulation from the dynamical impact of ENSO, with the latter mainly promoting the subtropical wave-breaking critical latitude poleward and pushing the midlatitude jet to higher latitudes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Role of Tropical Variability in Driving Decadal Shifts in the Southern Hemisphere Summertime Eddy-Driven Jet

The Southern Hemisphere summertime eddy-driven jet and storm tracks have shifted poleward over the recent few decades. In previous studies, explanations have mainly stressed the influence of external forcing in driving this trend. Here we examine the role of internal tropical SST variability in controlling the austral summer jet’s poleward migration, with a focus on interdecadal time scales. The role of external forcing and internal variability are isolated by using a hierarchy of Community Earth System Model version 1 (CESM1) simulations, including the pre-industrial control, large ensemble, and pacemaker runs. Model simulations suggest that in the early twenty-first century, both external forcing and internal tropical Pacific SST variability are important in driving a positive southern annular mode (SAM) phase and a poleward migration of the eddy-driven jet. Tropical Pacific SST variability, associated with the negative phase of the interdecadal Pacific oscillation (IPO), acts to shift the jet poleward over the southern Indian and southwestern Pacific Oceans and intensify the jet in the southeastern Pacific basin, while external forcing drives a significant poleward jet shift in the South Atlantic basin. In response to both external forcing and decadal Pacific SST variability, the transient eddy momentum flux convergence belt in the middle latitudes experiences a poleward migration due to the enhanced meridional temperature gradient, leading to a zonally symmetric southward migration of the eddy-driven jet. This mechanism distinguishes the influence of the IPO on the midlatitude circulation from the dynamical impact of ENSO, with the latter mainly promoting the subtropical wave-breaking critical latitude poleward and pushing the midlatitude jet to higher latitudes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Evaluation of a Reduced-Order Model for IBR Fault Response Representation via OEM Blackbox Models: Preprint

Driven by the need to capture the electromagnetic transients of transmission lines, inverter switching behavior, and detailed control systems, electromagnetic transient (EMT) studies have become increasingly important in industry, such as IBR interconnection study and fault study. However, original equipment manufacturer (OEM) inverter models typically include extensive parameters and proprietary settings that are unavailable to protection engineers. This paper introduces a data-driven, reduced-order model (ROM) developed as a PSCAD library component for use in EMT-based fault studies. The ROM replicates key OEM model behaviors without requiring detailed knowledge of control design or parameterization. The accompanying Python automation scripts streamline data generation, parameter fitting, and validation. The ROM's performance is demonstrated through comparison with both IEEE 2800-compliant and non-compliant OEM models in a real-world power system. Relay responses show nearly identical results, while simulation runtime is reduced by an average of 32.8\%, highlighting the ROM's practicality for protection engineers.

14 SOLAR ENERGY↗

DOE OSTI2023

Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned

Historically, regulatory barriers have precluded nuclear plant safety-related (SR) Instrumentation and Control (I&C) system modernizations. These barriers have been largely addressed by industry and United States Nuclear Regulatory Commission (NRC) efforts, including development of the License Amendment Request (LAR) Alternate Review (AR) process for digital I&C upgrades. The U.S. Department of Energy (DOE) and the Idaho National Laboratory (INL) are supporting a SR I&C pilot upgrade at the Limerick Generating Station (LGS) to demonstrate this process and capturing associated lessons learned for the benefit of industry. In 2021, a paper summarizing lessons learned as captured in INL/EXT-20-59809, Safety Related Instrumentation & Control Pilot Upgrade Initial Scoping Phase Implementation Report and Lessons Learned was presented at the 12th NPIC & HMIT conference. It is recommended that readers of this paper review reference 1 or the associated Nuclear Journal paper for context. This paper summarizes activities performed and lessons learned for the conceptual design phase and portions of the detailed design phase as captured in INL/RPT-23-XXXX, “Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned.” The portions of the effort covered by reference 2 include conceptual design phase activities from December 2020, through completion in November 2021, and detailed design activities through September 2022. These efforts and associated detailed documentation in reference 3 are intended to support similar industry upgrades as a foundation stone for a Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant total cost of ownership.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Load Control for Frequency Response - A Literature Review

As electricity grids employ greater fractions of renewable energy, which introduce additional variability and uncertainty in the net load, balancing electrical load and generation becomes more challenging. This paper reviews the literature documenting physical simulations and real systems that employ load control (LC) for frequency response and other grid services, which balance net load on the grid and prevent unwanted frequency excursions. Apart from academic and simulation studies, few sources exist on large-scale laboratory hardware testing or actual real-world systems that employ LC for frequency response, and we review them here. Four types of systems that we consider are: 1) Laboratory-based LC experiments, 2) Isolated microgrids that employ LC, 3) Larger grids that employ LC and 4) vehicle-to-grid (V2G) technology, using electric vehicles (EVs). In general, these systems have successfully used LC to meet their objectives, which are often keeping grid frequency within a required band. However, LC struggled to balance grid frequency in an isolated system powered by a single wind turbine, and V2G technology requires refinement in communication and control to provide optimal regulation that adheres to industry standards. As LC grows in the energy industry, we have three main recommendations: 1) encouraging system operators who use LC to publish system characteristics and lessons learned; 2) transitioning more LC theoretical/simulated systems to physical experiments, and physical experiments to real-world pilot systems; 3) demonstrating load control to support isolated, high-wind-contribution systems.

17 WIND ENERGY↗

DOE OSTI2024

Sentinel Devices LLC (CRADA Final Report)

Industrial equipment is a critical component of virtually all at-scale manufacturing and infrastructure. Broadly speaking, modern equipment is predominantly controlled using hardened digital controllers – computers designed to be able to operate continuously for sometimes extremely long periods of time, with little to no maintenance. Due to the nature of how these digital controllers have evolved, they are solely optimized to execute a single task, and do not have the capabilities or resources to monitor or analyze their internal state beyond simple execution of their program. As a result, for many “common sense” situations where individual data points can be easily determined to be out-of-normal, the controllers are unable to identify these incorrect operational modes unless a human has explicitly programmed in detection of this degradation. This project seeks to develop an AI/ML system which can identify incorrect or anomalous trends in industrial data streams, of exactly the kind that would be produced and seen by these digital controllers, with a minimal amount of computing resources. The benefits produced by developing this system would ultimately be self-monitoring and self-reporting infrastructure, capable of identifying and alerting humans to issues as soon as they happen, potentially long before they have the chance to impact the industrial process.

42 ENGINEERING↗

DOE OSTI2022

Controls Optimization Final Report, Controls Algorithms Report, Control Optimization - SPA II: Heaving Buoy Test Results [Three reports]

The over-arching project objective is to fully develop and validate optimal controls frameworks that can subsequently be applied widely to different WEC devices and concepts. Optimal controls of WEC devices represent a fundamental building block for WEC designers that must be considered as an integral part of every stage of device development. Using a building-blocks approach to optimal controls development, this effort will result in the full development of a feed-forward and feed-back control approach and a wave prediction system. Phase I focused primarily on numerical offline optimization and validation using wave tank testing of three industry partners’ WEC devices, including; CalWave, Ocean Energy, and Resolute Marine Energy. These industry partnerships allowed us to identify optimal control strategies for these different WEC topologies at different maturity levels. Phase II focused on demonstrating an integrated control system on an at-sea prototype that is to be custom-built and maturing the HW and SW required to successfully run our advanced controls code frameworks on at-sea systems. A secondary focus during phase II is to adapt our systems identification, controls and wave-prediction frameworks to become more robust and comprehensive in respect to RT capability, robustness, and reliability.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

In recent years, there has been considerable effort to modernize existing and new nuclear power plants with digital instrumentation and control systems (DI&C). However, there has also been considerable concern both by industry and regulatory bodies for the risk and consequence analysis of these systems. Of particular concern are digital common cause failures (CCFs) specifically related to software defects. These “misbehaviors” by the software can occur in both the control and monitoring of a system. While many new methods have been proposed to identify potential software failure modes, such as Systems-theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), etc., these methods are focused primarily on the control action pathway of a system. In contrast, the information feedback pathway lacks unsafe control actions (UCAs), which are typically related to software basic events; thus, assessment of software basic events in such systems is unclear. In this work, we present the idea of intermediate processors and unsafe information flow (UIF) to help safety analysts trace failure mechanisms in the feedback pathway and how they can be integrated into a fault tree for improved assessment capability. The concepts presented are demonstrated in two comprehensive case studies, a smart sensor integrated platform for unmanned autonomous vehicles and another on a representative advanced human system interface (HSI) for safety critical plant monitoring. The qualitative software basic events are identified, and a fault tree analysis is conducted based on a modified Redundancy-guided Systems-theoretic Hazard Analysis (RESHA) methodology. The case studies demonstrate the use of UIF and intermediate processors in the fault tree to improve traceability of software failures in highly complex digital instrumentation feedback. The improved method can also clarify fault tree construction when multiple component dependencies are present in the system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

A Generic FSC Wind Park EMT Model with IEEE Std 2800-Compliant Fault Ride-Through Capability

The modern power grid is seeing more and more electricity come from renewable sources like wind farms, which use sophisticated power electronics instead of traditional spinning generators. To keep everything running smoothly and meet industry standards such as IEEE 2800, these systems need smart control strategies. In our work, we built a flexible computer model of a full-scale wind farm converter that can handle grid disturbances without shutting down. When a fault or storm hits, the model’s built-in logic automatically adjusts the currents it sends to the grid and protects its internal energy storage, ensuring the wind farm stays connected and doesn’t damage its own equipment. Once the disturbance clears, the model restores normal operation seamlessly, so there’s no long interruption in power delivery. At the same time, it carefully regulates the voltage where the wind farm ties into the larger grid, helping to maintain safe voltage levels across the network. Our simulations show that this control setup not only meets all the requirements of IEEE Standard 2800 but also allows the wind farm to recover quickly and predictably, keeping the lights on no matter what happens on the grid.

17 WIND ENERGY↗