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This report is part of a series describing different ResStock measures. "Measures" refers to energy efficiency retrofits that can be applied to buildings during modeling. This documentation covers the "Advanced Air Sealing, Attic Floor Insulation, and Duct Sealing" measure upgrade methodology and briefly discusses key results.
This report is part of a series describing different ResStock measures. "Measures" refers to energy efficiency retrofits that can be applied to buildings during modeling. This documentation covers the "Advanced Air Sealing, Attic Floor Insulation, Duct Sealing and Insulation, and Drill-and-Fill Wall Insulation" measure upgrade methodology and briefly discusses key results.
This report is part of series describing a variety of different ResStock(TM) measures. "Measures" refers to energy efficiency retrofits that can be applied to buildings during modeling. This documentation covers the "Light Envelope" measure upgrade methodology and briefly discusses key results. All results can be accessed on the ResStock Open Energy Data Initiative "End-Use Load Profiles for the U.S. Building Stock" data lake and on the data viewer at resstock.nlr.gov.
Tamper-indicating devices (TIDs), also known as seals, play a crucial role in various sectors including international nuclear safeguards, arms control, domestic security, and commercial products, by ensuring that monitored or high-value items are not accessed undetected. These devices do not block access but alert to unauthorized tampering. With adversaries' capabilities evolving, there's a pressing need for seals to advance in terms of effectiveness (e.g., better tamper indication and unique identification), and new technology can improve the efficiency of installation and verification. Passive loop seals, widely used in international nuclear safeguards to ensure that continuity of knowledge is maintained on declared items, face stringent International Atomic Energy Agency (IAEA) requirements that surpass those met by commercial products. The metal cup seal (Figure 1, left), a staple IAEA seal, is robust but requires significant resources for post-use verification – specifically, the seal’s unique identity can only be verified at IAEA headquarters after removal from facilities. Further, the seal has been in use for decades and seal types should periodically be replaced to counter adversarial efforts for defeating seals. In 2020, the IAEA outlined about 40 requirements for a new passive loop seal, aiming for in-situ verification, minimal external tool use, unique identification (UID), and clear tamper indication. In response, research and development efforts focused on creating a new passive loop seal that meets these criteria and in 2022 the IAEA announced the completion of the Field Verifiable Passive Loop Seal (FVPS) (Figure 1, right). Concurrently to the IAEA’s efforts, Sandia National Laboratories (SNL) and Oak Ridge National Laboratory (ORNL) designed, developed, and tested two seal versions – Puck and Puck/SAW, with Puck based on the IAEA’s requirements and including a novel visually-obvious tamper response, and Puck/SAW adding additional beneficial capabilities like the ability to receive a unique identifier from a standoff distance and monitoring the wire integrity. Puck/SAW was specifically designed and developed to address sealing applications in dry spent fuel storage facilities, where the number of sealed spent fuel containers results in heavy verification burden and inspector safety issues related to radiation exposure. These efforts are described in this Executive Summary.
This is the final report for project DE-FE0031924 titled “High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines.” The report provides a summary of the entire project efforts from October 2020 through December 2024 including the high-temperature commercial dry gas seal (DGS) tests and thermal modeling of Task 2, as well as the high-temperature, large-diameter seal design and high-temperature tests of large-diameter seals in Task 3. A key outcome of Task 2 was the testing completion of specially instrumented commercial DGS in the GE-SwRI Apollo sCO 2 compressor (27,000 rpm). Test data from the DGS showed elevated temperatures upwards of 350 o F, which are close to the higher operating temperature limit of the DGS. The temperature measurements provide insight into the expected thermal loads on DGS operating in high-speed sCO 2 compressor and provided test data for validation of an in-house thermal model of the compressor/seal. Under Task 2.0, this report also presents the development of a steady-state conjugate heat-transfer model of the DGS operating in the sCO 2 compressor – a first of its kind model for modeling heat transfer of sCO 2 in an actual operating compressor. The findings of the thermal model show a reasonable match between temperature predictions of the model and the measured temperature data, also pointing out the validity of the approach and assumptions made in modeling the flows, heat transfer coefficients and windage modeling in the rig. Under Task 3.0, this report presents the preliminary design of a large-diameter hybrid face seal (14 inch and 26-inch diameter) for field testing in a land-based GE turbine. The preliminary seal design effort presented in this report under project DE-FE0031924 builds on the development and successful laboratory testing for such large diameter hybrid face seal under the prior DE-FE0024007 project. Key aspects of seal fluid analyses with CFD, mechanical design considerations and assembly considerations in a land-based turbine are presented. Finally, under Task 3.0, this report also presents the continued high-temperature testing of the 14-inch diameter hybrid face seal developed previously under the DE-FE0024007 program. Specifically, test data demonstrating successful non-contact seal operation and seal effective leakage of 0.001-inch with seal inlet temperatures above 700 o F are presented in this report. Successful hybrid seal operation in a laboratory environment for a large diameter (14-inch) seal at temperatures above 700 o F is a major technological milestone for this technology.
In turbomachinery, internal leakage flow accounts for up to 3% of the total thermodynamic cycle energy loss. Tradeoff must be made between the sealing efficiency (smaller clearance) and the friction and wear issues for interfering with the shaft (larger clearance). This ORNL-Danfoss joint effort developed a novel hybrid seal composed of carbon nanotube (CNT)-coated metal meshes. The CNT growth process was based on a self-catalyzing chemical vapor deposition and these multiwall CNTs were well aligned with high crystallinity. This hybrid material structure takes advantage of the CNT’s low-friction nature and uses the metal mesh as an extendable backbone. Full-scale experimental seals were designed, fabricated, and optimized for sealing performance and durability. The CNT-coated metal mesh seal demonstrated superior gas sealing efficiency to the baseline labyrinth seal and significantly improved shaft surface protection compared with the state-of-the-art superalloy brush seal on the static rig and full-scale compressor dynamometer tests. The CNT-metal mesh seal is low-cost and scalable and can potentially benefit wide applications, including CSP and other power generation, marine, automotive, and HVAC.
This document will briefly discuss the observations and results from an NREL conducted accelerated lifetime testing of the main shaft seal for the Verdant Power fifth generation Gen5 underwater Tidal Energy Converter (TEC) turbine, which successfully performed at the RITE project in 2020-2021. In order to evaluate a 5-year Service Interval ( SI) for this component, testing at NREL operated the main shaft seal nearly continuously for over 135 (text says 130 days on page 5 and 125 days on page 7 and 137 days on page 11) days at a rotational velocity of 160 rpm while the test stand recorded water pressure, barrier fluid pressure, temperature, and number of cycles., representing ~ 40% of the SI. An additional separate test was conducted to measure the aging behavior of the rubber drive rings. The water pressure reservoir was held constant as 29 psi. Barrier fluid pressure remained relatively constant throughout the duration of the test but was seen to sink to as low as 10.1 psi. No barrier fluid leakage was observed throughout the test. A sudden failure occurred within the seal after the power to test machine was interrupted for a scheduled building maintenance procedure. Upon restarting, the main shaft seal lost all ability to prevent water ingress. The exact cause is not known but is believed to be either a seal assembly issue or a change in the alignment of the seal components during or following the power outage. Following seal disassembly, significant wear was seen on one of the graphite sealing rings. Based on these results it is recommended that a follow-on TEAMER be conducted to rectify protocol and assembly issues to further evaluate SI of this component. The support and participation of Verdant Power Inc, Dovetail Solutions LLC and Garlock Manufacturing Inc were instrumental in understanding the results. NREL thanks them for their significant effort.
Sandia National Laboratories (SNL) is advancing technical capabilities used in passive loop seals. The “Puck” seal used a set of International Atomic Energy Agency (IAEA) requirements for new passive loop seals published in 2020 as a design guide. The seal is based on an oxygen-sensitive inner mixture encased in an oxygen-impermeable shell, is monolithic rather than two-part, incorporates self-capturing wire features, contains colored water beads and bubbles formed during processing as unique identifiers (UIDs), and visually indicates tamper (whether from seal body penetration or from seal wire removal) by irreversibly changing the seal body from multi-colored to black. This paper will provide details on the design, development, and testing of Puck seal prototypes.
This procedure applies to the loading of materials into quartz ampoules and flame sealing these ampoules. Flame sealed quartz ampoules are commonly used as a sealed containment for neutron irradiation. Due to the importance of maintaining containment for this application, this procedure involves a double encapsulation design wherein a sealed inner ampoule is sealed is in turn sealed within a larger diameter outer ampoule. General guidance for inspection of ampoules by destructive, non-destructive, qualitative (e.g., visual) and other methods are given. Materials to be placed inside the ampoules may consist of stable element materials or radioactive materials in either solid or liquid form. Liquids shall be dried prior to sealing the ampoule.
The Prospective Seal Unit Spatial Extent Database for U.S. Sedimentary Basins contains a series of spatial datasets representing spatial extents of publicly available data for caprock and seal rock units within the Appalachian Basin, Denver-Julesburg Basin, Great Valley Basin (Sacramento and San Joaquin Basins), Illinois Basin, Michigan Basin, San Juan Basin, U.S. Gulf Coast Basin, and Williston Basin. The database is designed to support carbon storage feasibility and resources assessment for carbon transport and storage (CTS) projects while displaying the spatial extent of prospective seal units and provide a guide to the original data source. This database leverages publicly available data resources from authoritative sources (e.g. U.S. Geological Survey, State Geologic Surveys, and published reports), and aims to help guide users to understand the seal unit's spatial coverage and data gaps from the regional to sub-basin/field scale. The database is organized by seal unit/formation, including the spatial extent for data found to be available for the seal unit. The various datasets represented include spatial extents of the lithologic formation, depth to top structural contour maps, and thickness/isopach maps. Included in this submission are the following resources: 1. Geodatabase/Dataset: “prospective-seal-unit-extents-2025.gdb” 2. ReadMe: “readme-prospective-seal-unit-spatial-extent-dataset-2025.pdf” 3. Data Catalog: “prospective-seal-unit-spatial-extents-data-catalog-2025.xlsx” 4. Data Sources Key: “data-source.csv” Please see NETL disclaimers here: https://netl.doe.gov/home/disclaimer
This report explores the best methods for aerosol envelope sealing of unoccupied, existing residences and documents typical leakage reductions. The project consisted of three distinct efforts: (1) scaled field demonstrations of the sealing process, tracking from setup to sealing and cleanup, (2) laboratory testing of new sealants that dry clear, making them more appropriate for retrofit applications, and (3) BEopt™ (Building Energy Optimization Tool) modeling of the energy implications of the measured reductions in leakage. Overall, aerosol sealing performance in existing homes was effective, with an average leakage reduction of 47% across all 34 sites. Conventional approaches typically only produce leakage reductions of 25%–30%. The aerosol sealing technology could provide a process for existing homes and multifamily units to gain the benefits of a well-sealed home at a reasonable cost with minimal disruption.
The goal of the Spatial Seal Database for Prospective Storage Resources in the USA is to provide relevant information and spatial extents of caprock and seal rocks. A lack of aggregated information is readily available that focuses on the caprock and seal units within sedimentary basins. The EPA class VI permit requires an assessment of the confining zone as part of submitting a permit. The data catalog of seal unit names and relevant properties with the seal spatial extent database aims to help provided important data for carbon storage based assessments. The data catalog and database are designed to show what seal data is available in a sedimentary basin and guide stakeholders to the original data source for those datasets.
According to recent studies and reports, in single-family houses (SFHs), air-sealing can significantly lower the thermal loads for space heating and cooling. Thus, air-sealing in SFHs could reduce the required size and cost of ground source heat pump (GSHP) systems for electrifying SFHs. Here, this study investigated the costs and benefits of integrating air-sealing with GSHPs for retrofitting existing SFHs when compared with air-source heat pumps. A whole building energy simulation tool integrated with an advanced design tool for modeling ground heat exchangers was used to calculate changes in required GSHP capacity, total borehole length, and building energy consumption with and without air-sealing in SFHs in 16 US climatic regions. The results from this study showed that reducing outdoor air infiltration from 0.8 air changes per hour (ACH) to the minimum ventilation requirement (0.35 ACH) can significantly reduce borehole length (up to 55 %), GSHP capacity (up to 48 %), and total heating electricity reduction, especially in cold climates (up to 44 %). The results also showed that for airtight homes (0.03 ACH infiltration) with a direct outdoor air system, the minimum required borehole length, GSHP capacity, and total heating electricity consumption can be reduced up to 70 %, 68 %, and 67 %, respectively, when compared with SFHs with 0.8 ACH infiltration. Moreover, the life cycle cost analysis showed that air-sealing in conjunction with a GSHP is more profitable than replacing the existing system with an air-source heat pump, even without any incentives for most climatic regions in the US (except for some hot regions).
Wave Energy Converters (WECs) rely on hydraulic Power Take-Off (PTO) systems to transform the kinetic energy of ocean waves into electricity, where hydraulic seals play a critical role in preventing fluid leakage and ensuring watertight operation under harsh marine conditions. However, seal degradation due to wear, fatigue, and corrosion remains a key challenge limiting system reliability and increasing maintenance costs. In this study, the tribological performance of elastomeric materials for hydraulic sealing applications that are based on commercial polyurethane and custom-compounded Ethylene Propylene Diene Monomer (EPDM) is investigated. Using a CSM tribometer, reciprocating wear tests were conducted in accordance with ASTM G133 under dry sliding conditions, with normal loads ranging from 3 to 10 N, and sliding speeds of 10 to 30 mm/s. Coefficient of friction (COF), specific wear rate, and worn surface morphology are evaluated to understand how load, velocity, and material composition affect seal durability. Improved wear stability and high Shore A hardness (93–94) were demonstrated by the commercial thermoplastic polyurethane (Duralast 4203 and 4758). EPDM-based compounds showed different filler-dependent behaviors, formulations filled with carbon black (E3) had the lowest wear rate (1.45 × 10?4 mm³ N?¹ m?¹) and increased load-bearing capacity, while samples modified with silica and plasticizer (E4, E5) had better conformability and damping but less hardness. Compounded EPDMs showed wider deformation zones because of their lower modulus and filler-matrix interfacial fluctuations, while commercial grades exhibited shallower wear scars (= 380 µm), according to optical profilometry. The Archard model-based lifetime estimation showed that, under 10 N and 30 mm/s, operational endurance ranged from 3.1 to 6.2 years. Because of its low wear rate and steady interfacial behavior, E3 had the longest anticipated life. For medium-load hydraulic sealing applications, these results demonstrate the possibility of customized EPDM formulations as affordable substitutes for commercial polyurethanes. They also offer a quantitative foundation for material selection and lifespan prediction.
Tamper-indicating seals protect sensitive materials, valuable equipment, and critical shipments. Most conventional seals must be checked through manual visual inspection and do not provide a digital record of their condition. Some attempts to remove, alter, or bypass a seal may also leave little visible damage, making tampering difficult to identify during routine inspections. Los Alamos National Laboratory has developed a smart tamper-indicating seal that converts even subtle tampering into a persistent digital record. The seal communicates its identity and status wirelessly through standard radio-frequency identification (RFID) readers, giving organizations a faster, more reliable way to verify that an asset has remained secure.
A seal assembly for a component of a turbomachine and method of assembly thereof is provided. The seal assembly includes at least one mating face positioned adjacent to the component and a seal coupled to the mating face. The seal includes an outer shell defining an interior space; an inner matrix filling the interior space comprising a plurality of unit cells comprising one or more metamaterials, wherein at least a portion of the plurality of unit cells are identical, and wherein the plurality of unit cells are repeated throughout the inner matrix; and one or more support struts extending throughout the inner matrix. The method of building the seal assembly may include selecting a first material for the outer shell and selecting the one or more metamaterials for the inner matrix based on the first material.
Atomically thin 2D materials present the potential for advancing membrane separations via a combination of high selectivity (from molecular sieving) and high permeance (due to atomic thinness). However, the creation of a high density of precise nanopores (narrow-size-distribution) over large areas in 2D materials remains challenging, and nonselective leakage from nanopore heterogeneity adversely impacts performance. Here, we demonstrate protein-enabled size-selective defect sealing (PDS) for atomically thin graphene membranes over centimeter scale areas by leveraging the size and reactivity of permeating proteins to preferentially seal larger nanopores (≥4 nm) while preserving a significant amount of smaller nanopores (via steric hindrance). Our defect-sealed nanoporous atomically thin membranes (NATMs) show stability up to ~35 days during size-selective diffusive separations with a model dialysis biomolecule fluorescein isothiocyanate (FITC)-Ficoll 70 in phosphate buffer saline (PBS) solution as well as outperform state-of-the-art commercially available dialysis membranes (molecular-weight-cutoff ~3.5–5 kDa and ~8–10 kDa) with significantly higher permeance for smaller solutes KCl (~0.66 nm) ~5.1–6 × 10 –5 ms –1 and vitamin B12 (B12, ~1.5 nm) ~2.8–4 × 10 –6 ms –1 compared to small protein lysozyme (Lz, ~4 nm) ~4–6.4 × 10 –8 m s –1 , thereby allowing unprecedented selectivity for B12/Lz ~70 and KCl/Lz ~1280. Our work introduces proteins as nanoscale tools for size-selective defect sealing in atomically thin membranes to overcome persistent issues and advance separations for dialysis, protein desalting, small molecule separations/purification, and other bioprocesses.
Widespread commercial adoption of ground source heat pumps (GSHP) is hindered by the relatively high initial cost associated with drilling boreholes in the ground to deploy ground heat exchangers. Reducing the energy demand of buildings has the potential to reduce the required borehole length and the associated drilling costs. In single-family residential buildings, air sealing can significantly lower heating energy usage, according to recent studies and reports. Thus, air sealing in conjunction with GSHP retrofits can lower the required GSHP system's capacity and borehole length to meet the thermal demands of the buildings. In order to understand the role of combining air sealing with GSHP retrofit quantitatively, the current study employs a whole building energy simulation tool integrated with an advanced design tool for the ground heat exchanger to determine changes in required GSHP capacity, total borehole length, and building energy consumption for with- and without-air sealing in single-family houses in 3 climate zones in the United States. The study considers one representative city for each climate zone, Phoenix, AZ for a hot climate, Seattle, WA for a moderate climate, and Minneapolis, MN for a cold climate. The results from this study show that reducing air infiltration from 0.8 ACH to the minimum ventilation requirement (0.35 ACH) can reduce borehole length requirement by up to 24% in Phoenix, 32% in Seattle, and 70% in Minneapolis. A similar magnitude of reduction can be seen for GSHP capacity and total building energy usage as well.