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DOE OSTI2024

Performance of cross-flow turbines with varying blade materials and unsupported blade span

Cross-flow turbines could play a larger role in the diversification of the global energy supply if the impact of more cost-competitive design choices on performance and rotor dynamics was better understood. This study focuses on rotor performance and blade strain measurements while varying the following parameters: blade materials and blade free end length by changing strut support position. Towing tank experiments were performed with a modular 1-meter diameter cross-flow turbine consisting of three NACA 0018 blades with two support struts. One strut was fixed at the lower end of the turbine, while the second strut was adjustable, thereby changing the length of the free end. The blade materials tested were carbon, E-glass, and hollow E-glass fiber composites, in decreasing order of stiffness and cost. High-resolution distributed fiber optic sensors were embedded in two of the three rotor blades for each material and provided hundreds of strain measurements per blade. Turbine performance and blade strain were measured while varying tow speed and tip speed ratio. Performance tests were conducted at towing speeds sufficiently high for the performance to be independent of Reynolds number. E-glass blades and carbon blades performed similarly for the most rigid strut configurations. Higher strain was measured on the E-glass blades, and their performance was reduced for less rigid configurations compared to the carbon fiber blades. The performance of the highly deflective hollow E-glass blades was lower overall and became even more degraded for longer unsupported blade span. Furthermore, the results provide insight into the use of various blade materials in cross-flow turbines and guidance on allowable free end length for each material type.

16 TIDAL AND WAVE POWER↗

DOE OSTI2026

Geothermal Heat Pump System Showcase: Short-Term Validation of Borehole Heat Exchanger Performance from Field Data to Numerical Modeling: Preprint

Since 2011, a geothermal heat pump (GHP) system has been operating to provide space heating and cooling for the Solar Radiation and Research Laboratory building at the National Laboratory of the Rockies (NLR) in Golden, Colorado. The system consists of 23 vertical boreholes, each extending to a depth of 300 ft (91 m), connected to 11 water-to-air heat pump units and four circulation pumps. Between fiscal years 2023 and 2025, additional power meters and temperature sensors were retrofitted to support detailed system performance assessment and model development. This study presents preliminary monitoring results and the development of an initial numerical model of the borehole heat exchanger field. The model incorporated site-specific geometry, ground thermal properties derived from thermal response tests, and ambient temperatures, and simulated system behavior over a representative operating day in September. Model predictions of outlet temperatures were compared against corresponding field measurements. Results showed that modeling initialized with a simplified linear subsurface temperature gradient presents systematic discrepancies in outlet temperature, whereas incorporating depth-resolved borehole temperature measurements for initialization yields substantially improved agreement with observations. The findings highlight the sensitivity of short-term predictive modeling to the representation of initial subsurface thermal conditions and underscore the value of high-resolution field measurements for model calibration and validation. These preliminary results inform ongoing efforts to extend the modeling framework to longer time horizons and to refine monitoring and modeling strategies that support the design guidance and operational optimization of GHP systems in research and commercial buildings.

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

Legacy Devices and Interoperability: Developing a Scientific Strategy for Inclusion and Representation of Older Devices

Legacy devices across grid, transportation, and building systems present complex modernization challenges that extend far beyond simple equipment obsolescence. Pulling from presentations and break-out group discussions from this workshop on legacy devices across all three sectors, this report examines the interconnected factors driving replacement decisions, documents successful modernization initiatives from recent years, and provides strategic guidance for coordinating infrastructure transformation across these critical sectors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Assessment of Condition Monitoring Methods and Technologies for Inservice Inspection and Testing of Nuclear Power Plant Components

This report was prepared for the U.S. Nuclear Regulatory Commission (NRC) to explore the application of advanced technologies toward meeting the current and future regulatory requirements for maintenance and condition monitoring of structures, systems, and components. The advanced technologies considered in this work are advanced sensors and instrumentation, data analytics, machine learning and artificial intelligence (ML/AI), physics-based models, and digital twins (DT). The interest in the application of advanced technologies for condition monitoring in nuclear power plants continues to grow, and current and future licensees are expected to implement advanced technologies as part of their inservice inspection (ISI) and inservice testing (IST) programs. This report delineates the outcomes of an exploratory investigation into the implementation of advanced condition monitoring technologies to address ISI and IST requirements. A thorough review was conducted of the existing regulatory requirements for ISI and IST, along with an analysis of associated industry practices. Additionally, a state-of-the-art assessment was performed on advanced condition monitoring technologies frequently employed in non-nuclear sectors. This research incorporated two nuclear-specific case studies to illustrate the application of these technologies within the current nuclear fleet. The report provides an exhaustive discussion on the technical challenges, considerations, and opportunities associated with the deployment of advanced condition monitoring technologies. The following are key considerations in the application of advanced technologies for the ISI and IST of nuclear power plant components: • Developing adequate verification and validation procedures to confirm the functional and non-functional requirements, • Developing technical capabilities to conduct real-time asset condition monitoring, • Establishing guidance and protocol for modeling and simulation tools to continuously meet regulatory requirements, • Addressing trustworthiness, explainability, and interpretability of ML/AI methods, • Evaluating maintenance activities to maintain an adequate safety margin and avoid undesirable conditions, • Establishing cybersecure condition monitoring programs associated with a computer-based software system, and • Establishing standardized evaluation metrics for advanced condition monitoring programs. Interest in the use of advanced technologies for condition monitoring in ISI and IST programs continues to grow, and the technology is expected to experience rapid and wide industry adoption in the near future. Adoption of advanced technologies for condition monitoring could have novel and unique impacts on regulatory activities associated with ISI and IST programs. The NRC is continuing to explore the regulatory aspects of advanced technologies as part of ISI and IST programs by pursuing additional research in this technical area.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Hydropower Black Start: A Guidebook for Retrofitting Grid Dependent Hydropower

Not all United States (US) hydropower plants were designed to provide black start, but they are increasingly needed to uphold resilience in the evolving electric grid. This guidance is designed to help understand the minimal retrofits required for grid dependent hydropower (GDH) plants behind the point of interconnection (POI). For distribution connected hydropower plants or those with dedicated cranking paths, such upgrades can be sufficient for the plant to provide black start. For others, more coordination with the transmission system operator will be needed. This guidebook answers a number of questions relevant to retrofitting hydropower plants with black start capabilities. For example, the guidebook answers: • How flexible do the wicket gate controls need to be? • Who needs to do hydro governor model validation, why, and how? • How robust and flexible do the excitation and AVR controls need to be? • What protection settings need to be adjusted? • What relay(s) will need to be bypassed or overridden and at what risk? • What is the electrical energy demand of the station load or auxiliary power systems? • What should the strategy to energize transformer(s) along cranking path to address inrush currents be? • How should the critical load restoration be sequenced? In addition to outlining the specifications that hydropower plants need to meet for each component to be able to perform black start, this guidebook provides a set of case studies for specific upgrades needed at actual plants. Between the case studies of plants that have already performed black start retrofits and the examples of how this guidebook can be applied to scope future retrofits, five key themes have been identified for retrofit needs. 1. Protection needs “black start” mode: hydropower plants that are not designed with black start capabilities will have protections that prevent them from interconnecting to a “dead bus.” These protections will need to be overridden in every retrofit case and a separate black start mode should be established so that operators can safely switch between black start and grid connected modes, minimizing the risk to the plant. 2. Wicket gates need modern controls: digital governors accelerate the parameter tuning process and gate position sensors improve controllability, so plants with mechanical governors should be upgraded. Furthermore, a black start and islanding mode should be established for controls to maximize plant performance. 3. Robust excitation support: the DC system or excitation generator needs to be reliable enough to form and sustain the rotor electromagnetic field. These systems are typically undersized in plants that were not designed for black start, so they will need to be upgraded. 4. Turbine-governor model validation and operator training: validation of a standard hydro governor model is needed to characterize the dynamic response (i.e., inertial and primary frequency response) of the GDH. This is required for control development and old hydropower plants often have outdated or incorrect models. Operator training is also typically required to ensure the hardware retrofits are utilized correctly during the black start process. 5. Transformer and cranking path energization: any upgradation and control adjustment in front of the POI will depend upon the existing interconnection. Coordination with the transmission or distribution operator may be required.

13 HYDRO ENERGY↗

DOE OSTI2025

Guidance for Developing Digital Twins for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable optimized scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins (DTs) are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. DTs for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. The promise of DT is that they may provide additional insights by combining and interpreting various sources of information and may be used for preventative maintenance scheduling optimization or early fault detection. DTs for condition monitoring are projected to be valuable for meeting requirements under 10 CFR 50.55a and 10 CFR 50.65. However, DT technologies are still under significant development and the process for developing a DT for condition monitoring has not been formalized. Therefore, in this work, we present an initial framework for developing a DT, discuss and review the various challenges and considerations for DT deployment, and identify the opportunities that a DT can improve. Here, the presented framework is intended to help developers formulate a strategy when approaching DT development for condition monitoring. A DT use case for a reactor coolant pump is presented to demonstrate the proposed framework.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗