Hybrid Directed Energy Deposition of Geometrically-Complex Pressure Vessels for Advanced HIP Canning and Digitally-Driven Powder Metallurgy
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Rodriguez Parra, Mario [ORNL]↗
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Using Information Automation and Human Technology Integration to Implement Integrated Operations for Nuclear
The purpose of the research effort described in this report is to develop and demonstrate an approach to the design and implementation of advanced, automated systems intended to increase operational efficiencies at nuclear power plants. In particular, we describe methods for considering human-technology integration (HTI) issues throughout the various phases of system design, test, and implementation and how these considerations help promote effective design. This research project will develop planning tools and comprehensive guidance on how HTI principles and methods, in combination with information automation technologies, can enable effective data integration and coordination for full nuclear plant modernization. Specifically, this research project will develop an approach to automate the mapping of data from plant systems and processes to application needs, thereby significantly reducing the amount of human workload currently required for the execution of these tasks. In addition to developing an automated solution as a replacement for these tasks, this research will also analyze digitalization’s effectiveness in reducing operational costs of compliance related activities. Compliance activities are estimated to account for as much as 50% of operations and maintenance (i.e., non-fuel and non-capital) costs of plant operation.
97 MATHEMATICS AND COMPUTING↗
Increased Interpretability for Model-Driven Deception: MARS LDRD Project
Machine learning has been proposed as a solution to several cybersecurity solutions and one of the most promising applications is for digital twins for intrusion detection and driving deceptive defense. However, machine learning techniques often result in a black-box function that is difficult for end users to interpret which for deception limits their ability to effectively define decoys. In this report, an approach to validate the equations learned are accurate is provided and demonstrated. Following, begins the process of addressing this issue for a model-driven deception technology that produces equations representing the physical process controlled by operation technology devices. This research was performed by applying subject matter expert context to machine learned models.
97 MATHEMATICS AND COMPUTING↗
GOOML (Geothermal Operational Optimization with Machine Learning) [SWR-23-01]
The Geothermal Operational Optimization with Machine Learning (GOOML) is a partnership between NREL and Upflow, NZ, awarded in response to the U.S. Department of Energy's Geothermal Technologies Office's Funding Opportunity Announcement (FOA) to expand the role of advanced analytics and automation in geothermal operations through machine learning. Partnering with industry (Contact Energy Limited ("Contact"), Ngati Tuwharetoa Geothermal Assets Limited ("NTGA"), Ormat Technologies Inc. ("Ormat") and Flow State Solutions Limited ("FSS"), GOOML was created to improve the operational efficiency of geothermal power plant steam fields through the analysis of historical operational data and the application of custom machine learning algorithms. NREL's contributions include machine learning, coding, and data management expertise as well as access to high-performance compute solutions. GOOML can increase geothermal operational efficiency through development of a digital system twin that can be utilized to provide optimal geothermal operating conditions for real-world geothermal fields. GOOML allows users to analyze field production histories in detail, develop models, and train machine learning algorithms to identify opportunities for increased geothermal efficiency, detect potential trouble, and allow predictive scenario modeling. Preliminary experiments have demonstrated a potential to increase total generation by as much as 12% through ML optimization of the utilization of existing steam field resources.
Buster, Grant↗
USACE FUSRAP Records Management Challenges in the Digital Age - 20242
In late 2016, the U.S. Army Corps of Engineers (USACE) implemented a Headquarters-supported nationwide records management initiative managed by the USACE-New England District to address the digitization and organization of Formerly Utilized Sites Remedial Action Program (FUSRAP) project files. This initiative will prepare USACE FUSRAP for moving toward a fully electronic system of records management. Additionally, the records management initiative streamlines the process and prepares the Administrative Record (AR) and Permanent Record (PR) file for transfer from USACE to the U.S. Department of Energy (DOE)-Office of Legacy Management (LM) following project closeout. Over the past couple of years, USACE and DOE-LM have been working to finalize a joint guidance document to assist in the FUSRAP records transition process. However, there remain key records management topics that require further discussion and development. Specifically, these topics include the implementation, process, and procedure for the capture of social media records and compliance with Section 508 of the Rehabilitation Act of 1973 (29 USC 794d), as amended. Due to advances in technology and the ease of communication it provides, USACE is using social media more often to interface with the public than 5, 10 or 15 years ago. The identification and capture of these records are challenging because it requires each USACE district or producer of a record to track what has been released through social media so that it can be captured as part of the AR or PR. USACE is currently evaluating processes and procedures for social media records capture. This paper explores how social media is being used by USACE across FUSRAP projects and best practices for the capture of social media records. Public accessibility to the project AR is required under the Comprehensive Environmental Response, Compensation, and Liability Act, which USACE FUSRAP must follow. As USACE FUSRAP ARs are converted to a digital format, greater accessibility to the files can be provided through web sites or other electronic media. However, Section 508 of the Rehabilitation Act must be considered when releasing electronic files to the public. Under Section 508, government agencies must ensure that information is made available to the public in a format that provides equal access to persons with disabilities. This paper discusses the electronic records requirements under Section 508 and addresses broad implementation of compliance across large digital records sets. Records management challenges are presented in the context of the FUSRAP records management program; however, these records management considerations and best practices are applicable across all Federal agency records management programs. Examples presented will further aid in understanding electronic records requirements that may be included on new USACE FUSRAP contracts as well as upcoming National Archives Records Administration requirements that will move us toward an electronic government. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
GBCGE Subsurface Database Explorer and APIs
This submission defines a DOI for the Great Basin Center for Geothermal Energy's (GBCGE) Subsurface Database Explorer web application and underlying data services, and acknowledges the INGENIOUS project as a major source of funding for data compilation and quality assurance. The GBCGE Subsurface Database Explorer is an interactive web mapping application that provides public access to the GBCGE Subsurface Database, and its collection of datasets pertinent to geothermal exploration, oil and gas exploration, critical mineral exploration, and other subsurface characterization for the Great Basin Region, western US. This is a living database, and will be continuously updated with new data and datasets as funding and motivations allow. The underlying database views that populate the web application are on an automated refresh schedule. Data sources and acknowledgements: We thank our partners with the Nevada Division of Minerals (NDOM), the Southern Methodist University (SMU), and Great Basin State Geological Surveys for their active efforts in data curation, schema design, and quality assurance. We also thank contributors among the USGS, Oregon Institute of Technology, State Divisions of Water Resources, State Divisions of Oil, Gas, and Minerals, and State Geological Surveys for open data availability and direct contributions made under the National Geothermal Data System (NGDS).
15 GEOTHERMAL ENERGY↗
Digital Twins for Nuclear Power Plants and Facilities
The nuclear digital twin (DT) is the virtual representation of a nuclear energy system across its lifecycle. The nuclear DT uses real-time information and other data sources to improve the process of design, licensing, construction, security, O&M, decommissioning, and waste disposal. By leveraging the knowledge base and experience from the past 40 years of LWR operation, the nuclear DT is helping to accelerate the development and deployment of advanced nuclear technology in areas of passive safety, new fuel forms, instrumentation, and reactor control. For the currently operating nuclear fleet, DTs are reducing the operational risks, increasing plant availability, increasing energy capability, and reducing electricity production costs. For advanced fission and fusion reactors, DTs are being used to design for passive safety and built-in security-by-design. Rapidly deployable small modular reactor (SMR) and microreactor designs compatible with modular construction techniques and advanced manufacturing will be the new normal, reducing the need for large capital expenditures and compressing construction schedules. In addition, lower operational and maintenance costs will be realized by reducing the complexity of operations, staffing needs, and maintenance-related activities.
Kropaczek, Dave↗
Computed Tomography Scanning and Petrophysical Measurements of the Wellington KGS 2-32 Core
This report describes the use of the computed tomography facilities and the Multi-Sensor Core Logger at the National Energy Technology Laboratory in Morgantown, West Virginia to characterize core from the Wellington KGS 2-32 well (API 15-191-22770). Core from the well was obtained as part of the Small-Scale Field Test Demonstrating Carbon Dioxide Sequestration in Arbuckle Saline Aquifer and by CO 2 -Enhanced Oil Recovery at Wellington Field, Sumner County, Kansas (DE-FE0006821). The primary impetus of this work was to capture a detailed a digital representation of the core from the Wellington KGS 2-32 well (Sumner County, Kansas). The collaboration between the U.S. Department of Energy’s (DOE) NETL and the Kansas Geological Survey (KGS) at the University of Kansas enables other research entities to access information about this potential carbon storage location and formations. The resultant datasets are presented in this report and can be accessed from NETL's Energy Data eXchange (EDX) online system using the following link: https://edx.netl.doe.gov/dataset/wellington2-32-core.
47 OTHER INSTRUMENTATION↗
AI-Enabled Discovery and Physics-Based Optimization of Energy Efficient Processing Strategies for Advanced Turbine Alloys (Final Technical Report)
In this project, the multi-organizational team of academic and industrial researchers from the University of Kentucky an aerospace and energy generation OEM partner has leveraged novel Digital Process Twin (DPT) models of process/structure interactions (i.e., process-induced surface integrity) to advance a paradigm of fully integrated computational materials engineering (ICME). Using efficient process models as the core of a digital process simulator for a reinforcement learning algorithm, the team has integrated industrial data and metrics of structure/performance/energy relationships and manufacturing-related energy metrics to optimize dynamic processing parameters for significantly improved life-cycle energy efficiency of advanced γ-TiAl low-pressure turbine (LPT) alloys, as indicated by a set of design relevant parameters (e.g., residual stresses and scrap rate). The key objective and anticipated outcome of the project was at least a 10% reduction in life-cycle embodied energy for a recently developed, γ-TiAl low-pressure turbine (LPT) alloy and nickel-based superalloy Inconel 718, through the adoption of the proposed AI-enabled process optimization approach. The final project outcomes significantly exceeded this original target, realizing manufacturing-related energy efficiency improvements of more than 130% for TiAl and up to 80% for Inconel 718. Rather than following the prevailing and highly inefficient empirical paradigm, the proposed study demonstrated the feasibility of adopting a digital, physics-based process design and optimization paradigm. The recurring need for manual intervention, rework, reinspection causes significant production bottlenecks and unnecessary expense associated with delivering the requisite component quality. The OEM partner, and turbine industry in general, expect to reap significant cost and resource savings if an AI-optimized set of parameters can be applied to specific machining operations. The technical scope of the proposed project involved the paving of a realistic path towards model-based and AI-enabled Integrated Computational Materials Engineering (ICME), and away from inefficient empirical process optimization and legacy manufacturing practices, which are no longer able to efficiently process novel high-performance turbine alloy materials. The project team will address the fundamental knowledge gap that currently exists within the ICME paradigm with respect to the process/structure/performance/energy impacts of finishing processes. While significant resources have been devoted to the ‘early stages’ of manufacturing, such as alloy design, primary and secondary processing, finishing processes have not been adequately integrated within ICME. To provide an actionable path towards model-based finishing process design (e.g., machining, burnishing, grinding, polishing), we will employ a novel AI-enabled process optimization paradigm, based on a computationally efficient, physics-based process simulator. Through limited experimental work to calibrate and validate our process simulator model via an advanced in-situ characterization technique and process optimization via reinforcement learning, the project will seek to demonstrate a viable alternative to the inefficient ‘legacy’ processing strategies, empirical testing and broad scope machining learning approaches, all of which fail to adequately consider complex process physics. The project team has identified an intermetallic γ-TiAl LPT alloy, which is currently being used as part of the OEM partner’s advanced gas turbine designs. This particular alloy poses significant manufacturing challenges during finishing operations, which limit the degree to which the current turbine design can be manufactured in an energy- and cost-efficient manner. Empirical testing and numerical modeling efforts to optimize processing parameters for γ-TiAl have not been able to resolve these manufacturing challenges, so the proposed physics-based AI-enabled optimization technology would offer a truly novel and transformative capability. The multi-organizational team of academic and industry experts from the UKY and the OEM partner will work together closely to demonstrate the analytical and experimental critical function and characteristic proof of concept of this novel approach.
20 FOSSIL-FUELED POWER PLANTS↗
Enabling the Electrification of Offshore Activities – Co-Demonstration of Next-Generation Autonomous Offshore Power System and Resident, Uncrewed Mobile and Static Assets at PacWave Wave Energy Test Site
Oceans cover two-thirds of the earth's surface and form the world's biggest and best – yet largely untapped – battery. Ocean waves have more energy density than other renewables, including wind, solar, and biomass, and have the potential to supply 4x the world's annual energy consumption (Masterson, 2022; Zic, 2020). In addition to the impact wave energy can have on decarbonizing and diversifying the electric grid, it offers a significant value proposition in the emerging blue economy sector (LiVecchi et al, 2019). The blue economy consists of industries operating offshore, including shipping, oil and gas, defense and security, aquaculture, and research. These industries require bringing people and energy on site to perform daily work, but current energy costs in the blue economy are extremely high. Here, the prevailing processes are complex, including shore dependencies and fuel transportation logistics. Few alternatives for reliable power generation exist, with the most prominent being high cost and high carbon emissions diesel generation. Because of this lack of affordable, reliable power, the trends of electrification, digitization, and automation that have led to substantial innovation and improvements in the terrestrial economy over the last two decades are slow to come to the blue economy.
16 TIDAL AND WAVE POWER↗
A functional form for liquid scintillator pulse shapes
Digitization of detector signals enables analysis of the original waveform to extract timing, particle identification, and energy deposition information. Here we present the use of analytical functions based on sigmoids to model and fit such pulse shapes from liquid organic scintillators, though the method should also be applicable to other detector systems. Neutron and gamma interactions in NE213 detectors were digitized from the phototube anode and fit using a sigmoid-based function. The acuity of the fit in extracting timing information and performing neutron-gamma pulse-shape discrimination are presented and discussed.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Expansion of the Fuel Motion Monitoring System
The Idaho National Laboratory (INL) Transient Reactor Test Facility (TREAT) Fuel Motion Monitoring System (FMMS) is a diagnostic tool used to visualize the movement and location of fuel within the nuclear reactor during transient experiments. TREAT is designed to test the behavior of nuclear fuel under accident conditions, such as a rapid power increase. The TREAT FMMS, also referred to as the “hodoscope” because of the system’s massive steel collimator component, is located on the North beam port of the reactor. While the FMMS system is capable of incorporating a total of 360 sensors, initial refurbishment efforts resulted in a array of 96 fast neutron detectors. This initial array was configured to provide a narrow (2 channels) full-length view of experiment vessels with an extended 4-channel–wide region in the center of the array capable of providing a full view of all initially planned experiments. Planning and efforts to expand the FMMS array began immediately following the restart of TREAT. An additional 96 detectors were evaluated, characterized, and prepared for installation at TREAT during the summer of 2018. Unfortunately, funding reductions forced the project towards a 5-year hiatus. In October of 2023 funding from the Department of Energy’s Nuclear Science User Facilities enabled the expansion to recommence. This report serves to document the activities performed to expand the FMMS detector array to 192 channels in order to provide a broader view of the larger and more sophisticated test capsules currently planned for future irradiation in the TREAT reactor. This expansion also included doubling the data acquisition capability, addressing the new heat load on the system, and synchronizing the time for all digital components.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
A Novel Decentralized PWM Interleaving Technique for Ripple Minimization in Series-Stacked DC-DC Converters: Preprint
Cascaded dc-dc converters are commonly used in applications where distributed energy sources or loads are connected to elevated voltage levels for power transfer. In such systems, it is advantageous to minimize the ripple on the bus current and voltage by proper phase shifting of the pulse-width modulation (PWM) pulses among the converters via a method known as interleaving. Existing approaches use either a centralized controller or separate communication lines among the stacked converters to control their relative PWM switch transitions. The key drawbacks are that these methods entail significant wiring, the central controller acts as a single point of failure, and implementation on very large numbers of units is impractical. In this paper, we introduce a decentralized interleaving control (DIC) strategy that acts on local current measurements at every converter and achieves communication-free PWM interleaving among the series-stacked converters. The proposed controller is simple in structure and is shown to converge asymptotically to the interleaved state irrespective of clock drifts among the digital signal processors. Experimental results are provided for a system of five series-connected converters showing a 10 times reduction in the current ripple compared to normal operation.
41 EE - Solar Energy Technologies Office (EE-4S)↗
Versatile High-Gain Low-Noise Readout ASIC for Silicon Microstrip Tracking Detectors
This work presents Turpial, a custom-designed low- power front-end readout ASIC for microstrip silicon sensors. Implemented in 130 nm CMOS technology, the chip integrates 64 identical readout channels, each including a configurable charge-sensitive amplifier, a bipolar pulse shaper, a 32-sample 50 Msps analog memory, and a 12-bit RC-hybrid SAR ADC operating at 1 Msps. To satisfy the target power budget of 5 mW per channel, the architecture employs a time-decoupled readout scheme in which fast transient signals are first captured in the analog memory and subsequently digitized at a lower rate. Turpial supports a wide dynamic range from 1 kℎ+ to 1 Mℎ+ while maintaining low noise performance, targeting an equivalent noise charge (ENC) below 200 𝑒−including the sensor, and providing a maximum gain of 1500 mV/fC. A digital block manages slow control, data acquisition, and data serialization through dual CML 300 Mb/s serializers. In addition, an on-chip reference circuit, based on a sub-1 V bandgap reference and an integrated LDO regulator, eliminates the need for external reference circuitry. Experimental results demonstrate that both the individual building blocks and the fully integrated ASIC meet the design specifications.
Hernandez, Hugo [Stanford University] (ORCID:00000↗
Considerations regarding the Use of Computer Vision Machine Learning in Safety-Related or Risk-Significant Applications in Nuclear Power Plants
With the advancements made to date in the field of artificial intelligence (AI), significant potential exists to utilize AI capabilities for nuclear power plant (NPP) applications. AI can replicate human decision making and it is usually faster and more accurate than humans. For implementations that impact critical NPP applications (e.g., safety-related or non-safety systems that potentially affect overall plant risk), a deeper safety analysis of the AI methods is necessary. AI applied to NPP operations could resemble the use of digital I&C (DI&C) because such applications involve digital computer hardware and custom-designed software that input plant data, execute complex software algorithms, and output the results to a system or licensed human operator to potentially provoke an action. For AI methods to be compliant with current safety requirements for DI&C, AI compatibility must be evaluated, and AI-related gaps may exist that prevent the prompt deployment of AI in NPPs. This effort aims to evaluate how example AI technologies align with the DI&C safety framework, and discusses how they could be analyzed, modeled, tested, and validated in a manner similar to typical DI&C technologies. Because AI is a broad field that encompasses areas such as machine learning (ML), natural language processing, and computer vision, this research focused on a subset of methods categorized as the computer vision ML (CVML) methods. This report explores two CVML use cases, gauge reading and fire watch, considered relevant to the DI&C standards, as they could play a safety-critical role. For the gauge reading use case, a CVML-enabled technology that can read gauges at oblique angles is utilized. For the fire watch use case, a CVML-enabled technology is utilized that migrates fire watch from a manual (human) approach to automated fire detection. These use cases are mainly intended to give context to the CVML system discussion. This effort assumes the worst-case scenario, with the CVML system being used to replace a safety-related or risk-significant system, thus requiring evaluation. Evaluating CVML against most of the relevant safety requirements for DI&C yielded several CVML-specific considerations due to the uniqueness of its characteristics in comparison with typical DI&C systems. For example, CVML models often employ commonly used (open-source) datasets, and it is not always possible to determine the level of overlap among open-source datasets. Therefore, the independence of the developed CVML models when demonstrating diversity is questionable, therefore creating vulnerability to common cause failure (CCF). The design verification process is also impacted since the data overlap could result in overestimation of the software validation and verification (V&V) performance results. Section 2 of this report evaluates a list of the identified CVML-specific characteristics and discusses the resulting considerations and potential solutions in the context of each referenced requirement. A summation is provided in Section 3. This report is not to be used as a guideline. It was developed to identify and consider issues in the implementation of ML technologies used to augment activities that may have a bearing on plant operation. The report draws parallels to the use of DI&C technologies, for which many standards are available to guide their use in nuclear plant operation. It considers the technologies and some of the potential implications of their use in safety-related applications but is not intended to address regulatory or licensing related issues.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Computed Tomography Scanning and Petrophysical Measurements of Oriskany Core across Eastern Ohio
The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize core material from three Ohio wells. These wells are listed below along with their American Petroleum Institute (API) and Ohio Geological Survey (OGS) identification numbers: - New York Central System 1 well (API 34085200170000, OGS Core 855) - Herren Well (API 34099201650000, OGS Core 2914) - Garvin-King Well (API 34121215610000, OGS Core 2939) The primary impetus of this work was to capture a detailed digital representation of the available core from all three wells. The collaboration between the U.S. Department of Energy’s (DOE) NETL and the Ohio Department of Natural Resources, Division of Geological Survey enables other research entities to access information about this potential carbon storage location and its surrounding formations.
58 GEOSCIENCES↗
Advanced Power-Hardware-in-the-Loop Evaluation of Inverter-Based Resources (IBRs)
Power-hardware-in-the-loop evaluation of IBRs has become more and more important as it provides reliable testing results to investigate the real responses of inverters with interconnected systems. A successful laboratory PHIL testing gives confidence of the hardware system to be deployed and de-risk technology integration prior to field deployment. So far, there are two important applications for PHIL evaluation: (1) test stability and functionality of large utility inverters into the system when it interconnects to the distribution systems/microgrids; and (2) test the collective grid service that inverters can provide to the grid. For the first application, the PHIL evaluation has high requirements for the stability and accuracy of the PHIL interface as the close-loop in digital real time simulator (DRTS) should replicate the actual current and voltage dynamics in the inverter. This is challenging because of the delays, sensing errors, nonlinearities of inverters, and hardware bandwidth limitations of the elements in the HIL loop. For the second application, multiple inverters will be tested resulting in multiple PCCs, which naturally causes competing dynamics and oscillations among hardware inverters if traditional PHIL interface is used. Therefore, new PHIL interface should be developed to compromise between stability and accuracy and represent the dispatched grid services for the hardware inverters. In this presentation, we will share our latest work in developing PHIL interface in these two applications to address the two key challenges.
DERMS↗
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↗