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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
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DOE OSTI2025

Building a Collaborative Relationship between Contractor and Oversight at SRPPF

The success of Department of Energy (DOE) projects is dependent on a functional, healthy, and collaborative relationship between the contractor and the federal oversight. A healthy relationship marked by a collaborative mindset between these two groups, can facilitate better operational safety, operational efficiency, and regulatory compliance. This paper will explore aspects of such a relationship, the roles and responsibilities of the contractor and federal oversight, the present and historical relationships in the DOE complex, and best practices considered by the contractor and federal oversight used at the Savannah River Plutonium Processing Facility (SRPPF) at the Savannah River Site (SRS). Due to the current design phase of the SRPPF, the contractor and federal oversight have a unique opportunity to begin establishing a strong relationship early in the project’s life. As a result of this dynamic, the two groups have already demonstrated their ability to successfully respond to ongoing design issues. In general, a strong criticality safety program is beginning to mature for the SRPPF alongside a developing criticality safety federal oversight group. This paper will discuss the various factors that have brought about this collaborative relationship. Lastly, a case study will be incorporated into this paper demonstrating the ability of the SRPPF contractor and federal oversight to overcome challenges relating to the SRPPF project. This case study may guide groups around the DOE Complex to create better, more functional relationships between the two parties. The case study will provide a detailed description of the issue and parties involved, highlight the factors that allowed the group to overcome the challenge via effective collaboration, and the outcome of the event. Increasing collaboration may benefit the complex, as a whole, in order to meet the mission demands of the DOE.

collaboration↗
DOE OSTI2026

When and Why Hiring and Training Occur: A Survey of Building Efficiency Contractors

As state and local governments, along with homeowners, work to enhance building energy performance, a sufficiently skilled energy-efficiency workforce is essential for implementing solutions at scale. In recent years, employers in the energy efficiency sector, including building performance contractors, have frequently reported challenges finding qualified workers. Additionally, as building performance technologies evolve and become more sophisticated, current workers need to acquire new skills and practices to maintain high-quality work. This study surveyed 209 contractors involved in building energy performance projects across 37 U.S. states, Washington, D.C., Guam, and the Marshall Islands. The survey aimed to understand their experiences in the labor market, their business practices, and their decision-making processes when hiring new workers and training existing employees. The findings highlight contractors' motivations and considerations in hiring and training, as well as the most significant challenges they face in the labor market. These insights can help workforce development practitioners design training programs that are aligned with workforce needs and responsive to employer concerns.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Unlocking the Path to Decarbonized Building Thermal Systems: Strategies for Designers and Contractors: Preprint

The design and construction community plays a pivotal role in facilitating the transition to decarbonized thermal systems that maintain human comfort while reducing building emissions. Through the U.S. Department of Energy Better Buildings initiative's Design and Construction Allies, a cohort of leading architecture, engineering, and construction firms have identified top ranked barriers that designers and contractors face when implementing solutions for building owners. These barriers to decarbonizing thermal - especially heating - systems include equipment availability; electrical capacity constraints; space allocations; complex system configurations; and lack of experience in designing, installing, and maintaining heat pumps. These impediments significantly amplify the risk and financial burden associated with the adoption of decarbonized solutions. The barriers also decrease the likelihood that designers, contractors, and owners will adopt decarbonization strategies without clear plans and guidance on how to implement these solutions, mitigate risk, and overcome the identified barriers. The National Renewable Energy Laboratory, the Design and Construction Allies, and the American Society of Heating, Refrigerating, and Air-Conditioning Engineers have developed "how to" thermal decarbonization guidance based on best practices. The subjects covered range from the role of energy efficiency in facilitating decarbonized heating solutions to strategies for decarbonizing new and existing heating, ventilating, and air-conditioning systems. The focus is on overcoming barriers so that energy-efficient, electrified buildings - both new and retrofit - become the industry standard. This paper outlines 1) the method used to collect and organize this guidance, 2) industry barriers to decarbonization, and 3) decarbonization techniques that have broad market applicability.

building heating↗
DOE OSTI2024

Realizing the Residential Electrification Opportunity: One Heat Pump at a Time

Space and water heating in residential buildings is a major contributor of greenhouse gas (GHG) emissions in the United States. Advanced electric heat pumps (HP) and heat pump water heaters (HPWH) are poised to provide a low carbon alternative to traditional fossil-based space and water heating. Widespread deployment of heat pumps could help address the significant portion of building emissions and primary energy used in American households, however much work needs to be done to close the knowledge gap between like-for-like fossil equipment replacement and switching to HPs for the average contractor. The Pacific Northwest National Laboratory (PNNL) has been working on closing this knowledge gap through the development of decision tools and resources targeted towards contractors and installers. Developed in coordination with stakeholders and experienced contractors from a variety of geographic regions, these tools help streamline the process of sizing and selecting residential HPs and HPWHs for key use cases. Along with the complementary Retrofit Decision Tool developed by PNNL, the decision tools will help contractors understand the importance of whole building considerations when choosing HPs including envelope upgrades, duct assessments, and electrical assessments to ensure optimal selection and performance of the HP or HPWH. They also provide direct links to resources and best practices developed by PNNL as well as external entities to further help contractor education and training. This paper describes the development of these tools, and their role in moving the existing space and water heating market towards HPs to help realize the country’s decarbonization goals.

heat pump, heat pump water heater, Residential bui↗
DOE OSTI2025

Design Basis Document / Owner’s Technical Specification for Nitrate Salt Systems in CSP Projects (Final Technical Report)

The number of commercial coal, gas, and nuclear projects built over the past 100 years number in the thousands. As such, there is a large database, available to a wide range of commercial engineering contractors, on proven designs. In essence, unsuccessful designs have, through generations of iterations, been identified and then deleted from further consideration. In contrast, the number of commercial parabolic trough projects using nitrate salt for the thermal storage media is perhaps 60. Further, the number of commercial central receiver projects using nitrate salt as the working fluid is on the order of 20, including estimates for China. Given the relative immaturity of salt technology, and commercial pressures to successfully bid new solar projects into a mature electricity market, solar projects often promise more than has been delivered. The Design Basis Document / Owner’s Technical Specification is a first step in the iteration process. The report describes the successful features of commercial projects, outlines a range equipment and system failures in projects that didn’t operate as intended, and provides a draft set of design changes intended to correct the known problems. The product of the study is 3 volumes of technical material; one volume is on parabolic trough technologies; a second is on central receiver technologies, and the third is on potential design changes to parabolic trough and central receiver projects. The 3 volumes, which total some 590 pages, can be found at https://www.solardynllc.com/csp-plant-technologies. One of the principal topics in the report is the use of functional or prescriptive specifications. Functional specifications describe what the equipment needs to do, consistent with the minimum legal requirements of the local jurisdictions. The details of how this is to be accomplished is developed by the engineering contractor. Prescriptive specifications, which are developed by the Owner, prescribe to the engineering contractor how the functional requirements are to be met. This arrangement ensures that the favorable experience from a previous project is repeated. One example is the design code for the hot salt tank in central receiver projects. The closest design basis is API Standard 650 Welded Steel Tanks for Oil Storage. However, the maximum design temperature in API 650 is 260 °C. As such, solar projects have typically adopted a hybrid Code approach, in which allowable material stresses are taken from ASME Section II Materials. Further, since the tanks experience daily changes in temperature and in (static) pressure, and since portions of the tank can operate at stresses beyond the elastic range, the low cycle fatigue life of the tank is conducted using the rules of Section VIII Division 2. However, in a recent study by NREL, the principal damage mechanism was identified as creep rather than fatigue. Further, design stresses permitted under Section VIII Division 2, corresponding to a fatigue life of 30 years, result in projected creep lifetimes of only 2 to 5 years. An alternate design approach, prescribed by the Owner, would be based on Code sections intended for high temperature service in the creep regime. A candidate is Section III Division 5. Granted, this is a nuclear code section, and it’s use would not likely be mandated by local jurisdictions. However, the effects of creep have been deemed to be of sufficient importance that one nuclear project developer, and one central receiver project developer, have stipulated in the tank design specification that the equipment be designed to the requirements of Section III Division 5.

14 SOLAR ENERGY↗
DOE OSTI2025

Flexible Fuel Electric Hybrid Glass Furnace Demonstration

The furnace contractor completed General Arrangement (GA) layouts and Piping and Instrumentation Diagrams (P&ID) for both furnaces during this reporting period. Preliminary equipment lists accompanied this work. Control system architecture in progress. Key furnace design elements and deliverables on track to be complete by end of phase. The facilities design and integration contractor completed a 3D scan and modeling of the facility. The work during this period focused on preliminary design with a focus on overall project scope and feasibility. This key work supports the overall project deliverables for 30% preliminary engineering and Preliminary Design Report (PDR) which are on track to be complete by the end of the phase. These deliverables are approximately 50% complete through the end of this reporting period. The batch house operations design contractor continues development of site plan and General Arrangement (GA) layout to support the 30% preliminary engineering and design package. This work is 60% complete by the end of this reporting period and is on track to be complete by the end of the phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Staged Z-Pinch Modeling with Hydra and Chicago Codes (CRADA Final Report)

This was a collaborative effort between Lawrence Livermore National Security, LLC (“Contractor”), as manager and operator of Lawrence Livermore National Laboratory (“LLNL”) and Magneto Inertial Fusion Technologies, Inc. ("MIFTI" or "Participant"), to develop staged Z-pinch (SZP) modeling with HYDRA and CHICAGO codes. The contractor performed numerical simulations of the SZP to reproduce and validate Participant’s MACH2 simulations. Contractor used the state-of-the-art, radiation-magneto-hydrodynamic code HYDRA, as well as the hybrid particle-in-cell code CHICAGO. This work helped assess the physical and numerical uncertainties associated with the simulations and the overall fusion scheme. HYDRA is a well-established and validated code. This work has helped to independently assess the SZP concept to give confidence to the Participant and to the broader fusion community.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

SPC-71123 Rev 1 MARVEL Control Drum Actuator Torsional Spring

Idaho National Laboratory (INL) is developing a microreactor to produce electrical power utilizing a small nuclear core under the Microreactor Application Research Validation and Evaluation (MARVEL) program. This specification defines the requirements for the procurement and factory acceptance testing of the MARVEL control drum actuator torsional spring. The purpose of this specification is to define the requirements to procure the MARVEL control drum actuator torsional spring component and witness a torsional spring rate Factory Acceptance Test (FAT) at the subcontractor’s facility with the contractor present. Any conflict between this specification and referenced Codes and Standards, or any supplementary specifications in the procurement documents requires written clarification from the Contractor prior to proceeding with any work. Any deviation from the procurement documents requires approval by the Contractor with the change request process.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2024

Tools And Methods to Analyze Plant Outage Schedule and Assist Schedulers in Improving Outage Resilience

Refueling outages of nuclear power plants (NPPs) are considered one of the most critical phases throughout the plant lifetime. In such instances, tens of thousands of activities (e.g., maintenance, surveillance) are performed in a short amount of time (typically 2-3 weeks unless major backfitting or modernization projects are carried out) by a large number of crews (e.g., electricians, mechanics) that are hired as contractors. As a consequence, a plant outage can be expensive not only in terms of costs (e.g., contractor labor, material), but also in terms of loss generation since the plant is taken off the grid during the full outage duration (an indicative metric is about 1.2M$/day of loss of revenue). Thus, there is a continuous need to decrease the economic impact of outages on plant finances. This can be done by: decreasing the frequency of plant outages (e.g., from 18 to 24 months), reducing the time to complete the outage, and reducing the risk of outage delays. The Optimization of Outage Activities project under the Risk Informed Systems Analysis Pathway (RISA) sponsored by Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program focuses on developing tools and methods to support NPPs with outage schedule optimization. The developed tools and methods are designed to analyze plant outage schedule with the goal of identify critical elements in the schedule that might pose a high risk of delays. These methods and tools can be considered resource-centric in the sense that they address outage challenges as a resource optimization problem. In this context, resources are either time and crews; outage delays occurs when either (or both) resources are insufficient to complete the set of tasks assigned at a specific time instant of the outage. This report provides details on how plant resources (time and crews) can be allocated in such a way that delays are minimized. In this respect, two classes of methods have been developed: the first one focuses on the time resource and how variability of the time to complete outage tasks may impact outage delays. The second one integrates available resources to assess when dailies activities should be performed such that the risk of outage delays are minimized.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Sustainable Polymer for Polyolefin Replacement (CRADA Final Report)

Sustainable Chemicals, LLC (Participant, Sust-Chem) develops renewable, biodegradable bioplastics for the replacement of large-volume petrochemical plastics such as polyethylene (PE) and polypropylene (PP). Participant’s patented bioplastics will find use in everyday items such as plastic bags, flexible containers, packaging, and toys and will address customers' ask for goods that are sustainable but don't cost a premium. Participants’ plastic comes from plant biomass and at the end of its lifecycle, is compostable or chemically recyclable. During the CRADA, Participant and Contractor will jointly refine the polymerization process used to make our bioplastic. Participant and Contractor will focus on technologies that are economically and industrially feasible, complete with full polymer characterization.

36 MATERIALS SCIENCE↗
DOE OSTI2025

2024 Annual Site Environmental Report for Sandia National Laboratories, Livermore, California

Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly-owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration. The National Nuclear Security Administration’s Sandia Field Office administers the Prime Contract and oversees contractor operations at Sandia National Laboratories, California. Activities at this multi-program engineering and science laboratory support the nuclear weapons stockpile program, energy and environmental research, homeland security, micro- and nanotechnologies, and basic science and engineering research. The U.S. Department of Energy’s National Nuclear Security Administration and its management and operating contractor are committed to fulfilling regulatory obligations, safeguarding the environment, assessing sustainability practices, and ensuring the validity and accuracy of the monitoring data presented in this annual site environmental report (ASER). This report provides a summary of environmental monitoring and compliance activities that occurred at Sandia National Laboratories, California, during calendar year 2024, unless noted otherwise. General site and environmental program information is also included. This report was prepared in accordance with DOE Order 231.1B, Admin Change 1, Environment, Safety and Health Reporting.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Design Basis Document / Owner’s Technical Specification for Nitrate Salt Systems in CSP Projects: Volume 1 Specifications for Parabolic Trough Projects, Volume 2 - Specifications for Central Receiver Projects, Volume 3 - Narrative

Design Basis Documents / Owner’s Technical Specifications are developed for parabolic trough and central receiver power plants using nitrate salt as the heat transport fluid and the thermal storage medium. The goals were to 1) distill the successful experience with nitrate salt systems from as many commercial projects as possible, 2) provide technical bases for equipment design/selection that an owner can impose on an EPC contractor, 3) compile this information in one location to provide guidance on salt systems that is as broadly applicable to as many projects as possible, and 4) work toward an industry consensus on a Design Basis Document that reflects the lessons learned from earlier commercial projects. The document allows an owner to provide design guidance, and to impose a minimum set of requirements, above and beyond those in the normal Codes and Standards, on an EPC contractor in an effort to avoid a repeat of past mistakes. If successful, this would allow salt systems to achieve the same levels of reliability and availability as commercial parabolic trough plants using diphenyl oxide / biphenyl (i.e., Dowtherm A, Therminol VP-1) as the heat transfer fluid. The report consists of 3 volumes: • Volume 1 - Specifications for Parabolic Trough Projects • Volume 2 - Specifications for Central Receiver Projects • Volume 3 - Narrative Volumes 1 and 2 include discussions of the following topics: • Plant functional requirements for the salt systems • Plant operating states, and transitions between states, for the salt systems • Risk analysis of the principal salt components • Plant requirements for the salt systems to meet the functional and the operating requirements • Type of specification for the principal salt components: functional; or prescriptive • Current state of the art for salt systems. Volume 3 discusses a number of cases in which the salt equipment at commercial parabolic trough and central receiver projects has not met the projected levels of reliability and availability. Possible reasons for the sources of the problems are discussed, as is a range of possible alternate designs that could avoid the known problems.

14 SOLAR ENERGY↗
DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturer (OEM)s. In addition to high strength for safety requirements, superior Self-Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight, and thus improving energy efficiency. The purpose of this project is to extend and validate an existing finite element code, which is based on the Contractor developed macro-micro multi-scale modeling approach, to numerically simulate the three-point bending and clinch test and study the influences of material microstructural characteristics and phase properties on the rivetability. The macro-micro modeling approach begins with a sample scale model and identify the location, which is mostly prone to failure, the deformation history of the boundaries of that location calculated will be used to drive a microstructure-based sub-models where the material microstructure and microscale properties are considered. Using this approach, the wrap-bending failure for two Al alloys are correctly predicted for the first time. This will start with phase I effort of building a framework of macro-micro three point bending test and clinch test of Al10SiMgMn HPDC alloy in the as-cast and T7 heat treated conditions. Those results will then be validated with experimental test results. The phase II effort will involve the utilization of the knowledge learned in phase I to establish the quantitative correlation between the microstructure characteristics and the riveting performance, which will be further used to guide the optimization of HPDC Al alloy microstructure using heat treatment process to achieve sufficient rivetability to join large thin-wall HPDC alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Automated segmentation and analysis of point clouds of pier foundations using Pier Inspection and Evaluation Report (PIER)

Pier foundations are commonly used in locations with unstable soil or where other types of foundations are unsuitable or cost prohibitive. A pier foundation consists of vertical columns to support the structure and elevate it above the ground. Common materials for pier foundations include masonry, concrete, timber, and steel. The methods for accurate placement of pier foundations have remained relatively unchanged for decades. For simple installations, construction chalk lines are used to layout the locations of piers to ensure accurate placement and elevation. For more complex installations, surveying instruments operated by trained professionals are employed to accurately locate piers and assess correct elevation before construction. After installation, another survey may need to be performed to assess the quality of the as-built foundation. However, with the advent of terrestrial laser scanners (TLS), the means now exist for contractors to conduct their own assessments of as-built foundations. The major barrier preventing contractors from performing their own assessments of as-built foundation quality is the segmentation and analysis of point cloud data, a skill that often requires a trained user. The objective of this research is to develop a software tool (PIER: Pier Inspection and Evaluation Report) to enable automated segmentation and analysis of point clouds of pier foundations. In this paper, the automated segmentation and analysis algorithms are detailed. A mockup lay out of pier foundations was built using concrete masonry units, and the algorithms were tested to evaluate performance. Limitations of the current algorithms and future research direction are discussed.

Turki, Amine [ORNL]↗
DOE OSTI2026

Next Generation Multi-Use Heavy-Duty High-Flow Direct-Fill Hydrogen Refueling Station with Standardized Design (CRADA Final Report)

The Contractor will build a liquid hydrogen (LH2) fueling station model that is capable of simulating the amount of hydrogen transferred from the liquid storage tank to the vehicle, depending on the station’s design and control scheme. This modeling work will allow the Parties to seek the design and control scheme of an LH2 station that can fill a targeted number of vehicles while meeting a time-average flow rate of 10 kg/min for each fill. While evaluating a high dispensing performance station design and control scheme, the Contractor will analyze the design and control scheme are economically viable.

08 HYDROGEN↗
DOE OSTI2025

Key Design Trades for a Near-term Lunar Fission Surface Power System

NASA and DOE have been developing concepts for lunar and Mars Fission Surface Power (FSP) systems for decades and have considered many different technologies and system variations. In 2023, three contractor teams completed Phase 1 conceptual design studies on a 40 kWe lunar FSP system in response to a modest set of NASA requirements and goals. A government team consisting of NASA Glenn Research Center (GRC), Los Alamos National Laboratory (LANL), and Idaho National Laboratory (INL) was formed to develop an independent design approach that adhered to the same requirements and goals posed to the contractor teams. GRC provided expertise, analysis, and design decisions for the power conversion, heat rejection, power management & distribution (PMAD), and mission integration. LANL and INL provided expertise, analysis, and design decisions for the reactor and shielding. The goal of the government study was to develop representative concepts that could be used in NASA architecture studies, guide government technology investments, and inform Phase 2 requirements definition. This paper provides a summary of the key technology options, system-level trades, and mission-level concept-of-operations.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Resources for Homeowners: Home Efficiency Upgrades

A fact sheet to support small business building contractors in communicating with homeowners about potential benefits of home efficiency strategies and suggestions for navigating home upgrades. This work was developed under the Building Business Network (B-Biz) program, which aims to improve adoption of high-performance building technology solutions by collaborating with organizations that support small business contractors that provide and service high-performance building technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Enhancing the ATR Primary Coolant System: A 3D Modeling Approach

The project consisted in system inspections to the ATR Primary Coolant System involving welds, fittings, motors, pumps, flanges, and heat exchangers to enhance Inservice Inspection program as required by DOE orders. NOTE: This article is to be published as "DOE & DOE Contractors Only" in the OPEXShare application, which means it will be available for viewing to DOE & DOE Contractor registered users only. This article can also be used by CAES for their training and safety meetings.

42 - ENGINEERING↗