Exoskeletons for DOE-EM and other Hazardous Operations
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Wheeler, Jason W.↗
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Results for “Operational Hazards”
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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Hazard and Operability Analysis for Operating, Refueling, and Maintenance of Fuel Cell Electric Buses
Since hydrogen vehicles can be implemented in heavy-duty transportation applications such as buses, it is important to understand safety hazards and risks of hydrogen fuel cell electric bus (FCEB) and refueling technology. We conducted a hazard and operability analysis for FCEB operation/driving, refueling, and maintenance/inspection. We identified failure modes and consequences and defined a qualitative risk metric as the product of the likelihood of a failure and the severity of the worst-ca
08 HYDROGEN↗
Hazard and Operability Study for the Ammonia Fuel Systems at the National Transportation Research Center
Oak Ridge National Laboratory’s (ORNL’s) Buildings and Transportation Science Division (BTSD) plans to operate research engines fueled by ammonia in two engine test cells at the National Transportation Research Center (NTRC). A scientific need has recently emerged to evaluate the suitability of liquid anhydrous ammonia as a low-lifecycle-carbon fuel source for difficult-to-electrify transportation sectors, including the marine sector. Therefore, BTSD plans to install an ammonia storage and delivery system to 2360 HVC engine research labs L125 (Cell 3) and L111 (Cell 7) capable of delivering 35 and 75 lb/h, respectively. These laboratories are specifically designed to allow for engine and fuels research and development, and they have existing safety systems for mitigating risks associated with toxics and flammables. Anhydrous ammonia is toxic and flammable, and the system will use relatively large quantities compared with standard gas bottles. Ammonia is one of the most widely produced chemicals in the world, and the hazards associated with toxicity and flammability are well understood. Ammonia storage for use in engine research at NTRC is anticipated to take the form of an ammonia tank with capacity of 1,000 water gallons; this quantity will remain below the threshold quantity of 10,000 lb (~2,000 gal) used both by the US Environmental Protection Agency for reporting under the Emergency Planning and Community Right to Know Act and for Risk Management Program requirements, and also by the US Occupational Safety and Health Administration for Process Safety Management requirements. ORNL’s Environmental Protection Services Division was also consulted to verify that the quantities of ammonia anticipated to be used would be in compliance with environmental regulations. The Environmental Protection Services Division staff confirmed that the anticipated quantities fall below ORNL’s permit thresholds. However, because of the hazards associated with anhydrous ammonia, the quantities to be used, and the limited experience with similar quantities of ammonia at ORNL, BTSD decided to perform a hazard and operability (HazOp) study on the ammonia storage and delivery system.
33 ADVANCED PROPULSION SYSTEMS↗
Evaporation Induced Entrainment of Contaminants from Evaporating and Burning Liquids.
This interim report details model development, theory, and a literature review focusing on the evaporation induced entrainment (sub-boiling) of contaminated liquids. Entrainment from a variety of sources is the topic of DOE Handbook 3010, and this report deals more broadly with fire related airborne sources of contaminants in hazardous operations. Relatively few studies have examined sub-boiling behavior in the past, however, it can be a phenomenon that presents a fire related risk under hazardous operations. Molecular dynamics simulations are used to infer the gaseous evolution of coordinated complexes, and a model for a water/plutonium/nitrate system is deduced from the simulation results by evaluating the statistical trends of the results. Questions remain as to the chemical reactivity and longevity of entrained species. A generalized computer model capability and simple analytical model assumptions are developed for predicting the results of these and other (boiling and solid entrainment) scenarios. Verification related predictions using these models are illustrated.
36 MATERIALS SCIENCE↗
MARVEL Hazard Evaluation ECAR-6440
MARVEL Hazards Evaluation evaluated the impacts of MARVEL operations, hazards, and postulated accidents. The hazard evaluation of MARVEL events and associated operations was performed for selection and evaluation of safety classification of systems, structures, and components (SSCs) and SSC safety functions, and for selection of design basis accidents (DBAs) applicable to the MARVEL microreactor design.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Smart Planning for Radioactive Source Transport Advanced Tools for Increased Safety and Efficiency
End-of-life (EOL) management of high-activity radioactive sources is made uniquely challenging by the inherent risks associated with storage and transportation of these sources, the complex logistics involved, and the strict requirements for regulatory compliance. Traditional methods lack comprehensive tools for accurate site assessments and precision planning for the transportation of radioactive sources. They also frequently fail to provide the adaptability required to consider diverse operational environments, resulting in inefficiencies and potential safety concerns. This paper introduces a novel software solution developed to address these issues by integrating advanced technologies such as light detection and ranging (LiDAR)-based 3D environment modeling, smart dynamic route planning, and customizable measurement functionalities. This software enables detailed terrain visualizations, facilitating thorough environmental assessments and enabling users to virtually navigate, analyze, and plan site-specific operations. Among the key features are a user-centric interface for virtual navigation, precise site measurement tools for site evaluations, interactive visualizations that highlight potential operational hazards, dynamic route planning capabilities, and real-time collision detection to promote safe workflows. By demonstrating the effectiveness of this tool through real-world application, the present work underscores the tool’s potential to revolutionize radioactive source EOL management by improving operational efficiencies, minimizing risk, and advancing the state of practice to achieve suitable and secure radioactive material handling.
99 - GENERAL AND MISCELLANEOUS↗
Removal of deuterium retained in boron powder by oxygen or high-temperature bakeout
Fuel retention in dust accumulated in fusion devices is a potential operational hazard. Boronization is one of the leading wall-conditioning candidates for future fusion devices. Fuel retention characteristics of boron dust must be studied to accurately understand the potential hazards of boron dust in fusion devices. We evaluated the retention of deuterium (D) in commercially available boron powder as a proxy for tritium retention in boron dust. Diffuse reflectance infrared Fourier transform spectroscopy revealed that boron powder between 300 and 500 K exposed to neutral hydrogen (H 2 ) gas retains H via B-H bonding. We utilized D 2 exposures of 17,400 L on the boron powder, which led to retention on the order of 0.5 g D per 100 kg B or 1.2 g D per m 2 B, as estimated from temperature programmed desorption measurements. We evaluated how powder bakeouts under ultra-high vacuum (UHV), or in an oxygen (O 2 ) or H 2 gas backfilled environment can remove the retained fuel. Bakeouts below 523 K under UHV exhibited poor D removal, promoting recapture of D 2 present as background gas in the chamber. Higher temperature bakeouts led to the removal of over 80% of the retained D within 3 days (623 K) or 1 h (723 K). Bakeouts at 423 K under an O 2 gas environment removed ∼150% more retained D from the boron powder, when compared to bakeouts conducted under UHV. These results suggest that efficient fuel removal from boron dust can be achieved by high-temperature bakeout (>623 K) or by bakeouts at lower temperature (423 K) under an O 2 environment.
Bakeout↗
Characterization of 3D printing filaments containing metal additives and their particulate emissions
Polylactic acid (PLA) filaments are widely used in fused filament fabrication (FFF) processes (3D printing). Filament additives such as metallic particles incorporated into PLA to modify functional and aesthetic features of print objects are becoming increasingly popular. However, the identities and concentrations of low percentage and trace metals in these filaments have not been well described in either the literature or product safety information included with the product. Here, we report the structures and concentrations of metals in selected Copperfill, Bronzefill and Steelfill filaments. We also report size-weighted number concentrations and size-weighted mass concentrations of particulate emissions as a function of print temperature for each filament. Particulate emissions were heterogenous in shape and size with airborne particles below 50 nm diameter dominating the size-weighted particle concentrations and larger particles (approximately 300 nm) dominating the mass weighted particle concentration. Results indicate that potential exposure to particles in the nano-size range increase when using print temperatures above 200o C. Because inhalation exposure to nanoparticles has been linked to adverse health outcomes, we suggest that using lower print temperatures for specific metal-fill filaments may reduce their operational hazard.
36 MATERIALS SCIENCE↗
Solvent processing for improved separation of hydrothermal liquefaction products
Solvent extraction and separation of HTL products using naphtha range hydrocarbons was studied with the aim of decreasing operational hazards while improving scalability, reliability, and yields.
09 BIOMASS FUELS↗
Sandia SWiFT Facility Site Operations Manual
The Scaled Wind Farm Technology (SWiFT) site, operated by Sandia National Laboratories for the U.S. Department of Energy’s Wind and Water Power Program, was commissioned in 2013 as a research facility with multiple wind turbines at a scale useful for the experimental study of wake dynamics, advanced rotor development, turbine control, and advanced sensing at production-scale wind farms. This manual provides an overview of facility operations, hazards and safety controls, and emergency response procedures at the site and is required reading for all SWiFT staff and Sandia workers, collaborators, and contractors who perform work on the site.
17 WIND ENERGY↗
Development of NDE/NDT Tools for High-Volume & High-Speed Inspection of CFRP Structures in Automotive Manufacturing
Main advantages of the air-coupled ultrasound testing (ACUT) and electromagnetic testing (EMT) techniques for NDE of CFRP composites were non-contact sensing, scalability for high-speed inspection, cost-effectiveness, and non-hazardous operation. Despite these advantages, no systems that would satisfy the project requirements were commercially available. Hence, one of the major efforts of the Michigan State University (MSU) team at the initial stage of the project was to close this technological gap by developing, optimizing, and validating array sensors that would provide sufficient sensitivity, spatial coverage, and resolution for robust defect detection. Optimization of the ACUT and EMT sensor designs was performed using experimentally validated finite element models. Initial experiments using array probes were conducted on relatively flat CFRP samples. In parallel, the MSU team designed and assembled a portable platform with two robotic arms. The robots were equipped with newly designed sensors that enabled high-speed NDE of curved CFRP parts. Presently, the developed robotic platform can be used as a demo/template NDE system, which is easily adaptable to manufacturing environments and in-line NDE. The ACUT NDE system developed by the MSU team used a high-power 4-channel pulser receiver for parallel data acquisition. The array probes were designed by stacking commercially available ACUT transducers, which operated in the frequency range between 100 kHz and 500 kHz. MSU optimized the excitation procedure and developed wave focusing cones so as to reduce the crosstalk between the transducers and to provide higher pulse repletion frequency (PRF). The through-transmission (TT) and single-side access (SSA) inspection modes were successfully implemented. In the TT-ACUT, structural defects in CFRP were detected by passing ultrasonic waves through the test part. Hence, the ACUT transmitters and receivers needed to be placed on the opposite sides of the test part. In the SSA-ACUT, guided waves (GW) were excited in the test part using the transmitters and were sensed by the receivers from the same side. Multi-channel TT-ACUT and SSA-ACUT provided high-speed NDE, and were successfully validated on CFRP test samples with interlaminar delaminations and other embedded defects The EM techniques developed by the MSU team included: 1) eddy current testing (ECT), 2) capacitive imaging (CI) and hybrid dual-mode imaging. In ECT, structural damage was detected in CFRP using coils sensor arrays. In ECT, the excitation magnetic field is generated by passing an alternating current through a coil, which is placed above the test sample. The excitation field penetrates the conductive sample and induces the eddy currents in its transect. In turn, the eddy currents generate the reaction field, which affects the total field sensed by a coil. Hence, the presence of structural flaws will alter the eddy current flow and the picked-up signal. ECT is mostly sensitive to local changes of the electric conductivity of the test sample, and CFRPs are mostly conductive in the direction of carbon fibers. Hence, ECT was well suited for the detection of fiber damage/fiber irregularities. The MSU team developed printed circuit boards (PCB) with coil sensor arrays optimized for NDE of CFRP. Unlike most commercial probes designed for ECT of metallic structures, the MSU array probes were designed for operation in [1-10] MHz frequency range, which was optimal for low-conductive CFRP. Multiple sensing topologies (coil groups excitation/sensing arrangements) were implemented and successfully validated. Capacitive Imaging (CI) technique developed by MSU was complementary to ECT. In contrast to ECT, which was sensitive to local changes of the electrical conductivity, the CI was sensitive to local changes of the dielectric constant. Therefore, CI could provide information about matrix damage/matrix irregularities in CFRP. The MSU CI sensor arrays were made of multiple circular or rectangular open-plate capacitors printed on PCB. Sensors of this type are not commercially available. In addition to ECT and CI, the MSU team developed a hybrid (dual-mode) inductive/capacitive measurement technique that synergistically combined the benefits of inductive and capacitive sensing for rapid NDE of fiber reinforced polymer (FRP) composite structures. Fiber damage and fiber irregularities in FRPs were detected by configuring hybrid sensors as coil sensors. Similarly, matrix damage, matrix irregularities and interlaminar delaminations were detected by configuring hybrid sensors as capacitive sensors. ECT and CI were performed sequentially by means of electronic switching. Hence, eliminating the need for mounting two separate sensor arrays on the probe. Portable robotic platform was developed by MSU for multi-technique high-speed NDE of CFRP test parts. The platform had two 6-axis robots, which enabled inspection of curved parts in approximately a 6×6×6 ft 3 active scan area. On the software side, the MSU team integrated scripts for NDE hardware control with scripts for robot motion control. MSU also implemented automated path planning for the robots, reconstruction of part’s surfaces via stereovision, 3D rendering of inspection data, and image processing algorithms for enhanced defect detection. Automotive composite parts manufactured by Plasan Composites from Phase I were used to validate the ACUT and EMT techniques on representative testbeds. Among those parts were three X-braces for a Dodge Viper, one composite calibration plaque with known defects at known locations, and four other test sections, including sections from a front splitter, a corner section from a composite hood, and a high-pressure RTM panel made using non crimp fabric. Other test samples included CFRP and GFRP calibration plates with fiber/matrix defects fabricated at MSU/CVRC.
36 MATERIALS SCIENCE↗
Editorial: Predicting near-earth space environment: new perspective and capabilities in the AI age
Editorial on the Research Topic Predicting near-earth space environment: new perspective and capabilities in the AI age The near-Earth space environment is not only an operational hazard for space missions, but also a scientific laboratory for advancing our understanding and prediction of space plasma populations. This Research Topic is organized around three interconnected themes: observational datasets, machine-learning (ML) model development, and the discovery of new physical insights through those models. Its primary goal is to highlight the emerging capabilities in space environment prediction that are enabled, or will be enabled, by integrating advanced techniques—including AI/ML methods—with long-term curated datasets.
58 GEOSCIENCES↗
MODIFICATION OF THE SPAR-H METHOD TO SUPPORT HRA FOR LEVEL 2 PSA
Currently, available Human Reliability Analysis (HRA) methods were generally developed to support Level 1 Probabilistic Safety Analysis (PSA) models. There has been an increased emphasis placed on Level 2 PSA in recent years; however, the currently used HRA methods are not ideal for this application, including the SPAR-H method. Challenges that will likely be present during a severe accident such as degraded or hazardous operating conditions, shift in control from the main control room to the technical support center, unavailability of instrumentation, and others are not routinely considered for Level 1 HRA analysis. These factors combine to create a much more uncertain condition to be accounted for in the HRA analysis. While the SPAR-H shaping factors were established to support Level 1 HRA, previous studies have shown it may be used for Level 2 HRA analysis as well. The Canadian Nuclear Safety Commission (CNSC) and Idaho National Laboratory (INL) in a joint project are investigating modifications to the SPAR-H method to create more consistency in applying the performance shaping factors used in the method for Level 2 analysis.
99 GENERAL AND MISCELLANEOUS↗
Enhancing Operational Safety via Agentic Dialogue Hazard Identification Analysis
Operational safety in high-stakes domains such as industrial process control, autonomous, and safety-critical systems demand reliable hazard identification. While large language models (LLMs) have shown promise in automating safety analysis tasks, single-turn, monolithic inference is brittle: it lacks the self-correction, deliberation, and contextual refinement that safety engineers apply iteratively. In this paper, we introduce HAZDIAL, a framework that investigates whether structured agentic dialogue (multi-agent, multi-turn interactions) improves the quality of NLP-based hazard identification over single-pass baselines. We systematically compare two dialogue modalities: adversarial debate and constructive discussion, and propose an genetic algorithm-based agentic interaction optimization. We evaluate all configurations against a curated golden dataset using standard classification metrics (accuracy, precision, recall, F1) and a novel dialogue metrics. This work advances the intersection of dialogue systems, multi-agent reasoning, and AI safety, providing empirical evidence for dialogue-driven hazard analysis.
Das, Sanjay [ORNL] (ORCID:0009000542591915)↗
Impact of Extreme Weather and Natural Hazards on Grid Operations: A Focus on Utility-Scale Solar
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Jackson, Nicole Danielle↗
Evaluation of Heliostat Standby Aiming Strategies to Reduce Avian Flux Hazards and Impacts on Operational Performance
This paper presents a study of alternative heliostat standby aiming strategies and their impact on avian flux hazards and operational performance of a concentrating solar power plant. A mathematical model was developed that predicts the bird-feather temperature as a function of solar irradiance, thermal emittance, convection, and thermal properties of the feather. The irradiance distribution in the airspace above the Ivanpah Unit 2 heliostat field was simulated using a ray-trace model for two different times of the day, four days of the year, and nine different standby aiming strategies. The impact of the alternative aiming strategies on operational performance was assessed by comparing the heliostat slew times from standby position to the receiver for the different aiming strategies. Increased slew times increased a proxy start-up time that reduced the simulated annual energy production. Results showed that spreading the radial aim points around the receiver to a distance of ~150 m or greater reduced the hazardous exposure times that the feather temperature exceeded the hazard metric of 160 degrees C. The hazardous exposure times were reduced by ~23% and 90% at a radial spread of aim points extending to 150 m and 250 m, respectively, but the simulated annual energy production decreased as a result of increased slew times. Single point-focus aiming strategies were also evaluated, but these strategies increased the exposure hazard relative to other aiming strategies.
14 SOLAR ENERGY↗
Feasibility Analyses for the Microgrid of the Mountain in the Cordillera Central Region of Puerto Rico
Distributed energy resource (DER) development can benefit communities through improvement of access to reliable electricity and a resilient energy system. Many place-specific considerations must be accounted for when designing electrical systems with co-located generation and loads. This paper presents an overview of four studies focusing on different aspects for regional DER development in the Cordillera Central region of Puerto Rico, including a grid and load stability study with the introduction of solar energy generation, microgrid design based on the solar resource in the area, resilience considerations during power outage scenarios, and qualitative risk aspects for components in the microgrid. Additionally, a conceptual substation microgrid analysis is conducted using the Microgrid Design Toolkit (MDT) to evaluate trade-offs between cost and energy availability, providing insights into optimal design strategies. A microgrid resilience assessment is performed using the Resilient Nodal Cluster Analysis Tool (ReNCAT) to identify critical loads and evaluates their accessibility during outages, emphasizing the importance of community needs. Finally, a qualitative risk assessment utilizing Hazard and Operability Analysis (HAZOP) methods highlights potential hazards and mitigations for microgrid components, ensuring robust system design and operation.
24 POWER TRANSMISSION AND DISTRIBUTION↗
A tri-level optimization model for interdependent infrastructure network resilience against compound hazard events
Resilient operation of interdependent infrastructures against compound hazard events is essential for maintaining societal well-being. To address consequence assessment challenges in this problem space, we propose a novel policy-guided tri-level optimization model applied to a proof-of-concept case study with fuel distribution and transportation networks – encompassing one realistic network; one fictitious, yet realistic network; as well as networks drawn from three synthetic distributions. Mathematically, our approach takes the form of a defender-attacker-defender (DAD) model—a multi-agent tri-level optimization, comprised of a defender, attacker, and an operator acting in sequence. Here, in this study, our notional operator may choose proxy actions to operate an interdependent system comprised of fuel terminals and gas stations (functioning as supplies) and a transportation network with traffic flow (functioning as demand) to minimize unmet demand at gas stations. A notional attacker aims to hypothetically disrupt normal operations by reducing supply at the supply terminals, and the notional defender aims to identify best proxy defense policy options which include hardening supply terminals or allowing alternative distribution methods such as trucking reserve supplies. We solve our DAD formulation at a metropolitan scale and present practical defense policy insights against hypothetical compound hazards. We demonstrate the generalizability of our framework by presenting results for a realistic network; a fictitious, yet realistic network; as well as for three networks drawn from synthetic distributions. Additionally, we demonstrate the scalability of the framework by investigating runtime performance as a function of the network size. Steps for future research are also discussed.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗