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DOE OSTI2025

Developing and Implementing Risk-Based Research Safety at Argonne National Laboratory

Facilities operated by the US Department of Energy (DOE) are required to have extensive worker safety and health programs by regulation. Here we describe how Argonne National Laboratory (ANL) has implemented the DOE requirements to bring the Laboratory’s multidisciplinary research risk to an acceptable level to safely execute ANL’s mission to perform cutting-edge research.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Coupled Thermo-Hydrological-Mechanical-Chemical Behavior of Anisotropic Granite for Geologic Disposal of High-Level Radioactive Waste: A Core-Scale Laboratory Investigation

The coupled thermo-hydrological-mechanical-chemical (THMC) behavior of rock within an Excavation Damaged Zone (EDZ) is critical for the safety and long-term performance of a geological repository for high-level radioactive wastes. While many laboratory experiments have been conducted to investigate EDZ rocks, the flow and deformation characteristics resulting from anisotropic rock textures and microcrack distribution under triaxial loading and elevated temperatures remain poorly understood. Particularly, cracks at various scales serve as fast paths for fluid flow and solute transport and present as focal points of mechanical weakness, which complicate the coupled THMC processes in anisotropic EDZ rocks and challenge modeling predictions. Here, in this study, a series of core-scale experiments was conducted on three granite samples under repository-relevant conditions. These rock samples were obtained from the Grimsel Underground Research Laboratory (URL), featured by anisotropic minerals (represented by bedding layers) and microcrack distributions and coarse cm-scale grain sizes. During the experiments, samples were subjected to an elevated temperature at 90 °C and different triaxial loading conditions either by radial (normal to bedding layers) or axial (parallel to bedding layers) compaction. Water was injected into the samples, and the rock permeability evolutions and effluent water chemistry were monitored closely. For intact samples, thermal expansion of minerals at 90 °C resulted in a large, 75% irreversible permeability reduction and rock strengthening under radial compaction, while thermal impact was limited to a 15% permeability reduction under axial compaction. In contrast, for a sample containing open cracks, the growth of fractures during the experiment resulted in an abrupt permeability increase and fast failure at 90 °C. The effluent water chemistry indicates much more considerable mineral dissolution from large shear sliding than that in rocks dominated by mechanical compaction. These results helped better understand the coupled THMC processes in anisotropic rocks containing cracks, evaluate the behaviors of EDZ rocks, and predict the long-term evolution of EDZ for the performance of the repositories.

Coupled THMC processes↗

NASA NTRSDate not supplied

Thin-Film Embedded Sensors for Battery Health Monitoring

Hybrid or all-electric aircraft are being developed as the next generation of aircraft to both allow new forms of aviation and decrease environmental impact. Since these types of aircraft are based on high-capacity battery technology, safe operation of these batteries becomes increasingly important. In particular, the potential for battery failure due to uncontrolled chemical reactions resulting in thermal runaway, catastrophic failure, and battery fires must be addressed in order for such battery technology to have the level of safety needed for standard aviation implementation. Efforts to ensure battery safety often involve engineering solutions that seek to contain rather than prevent such events by early detection. Such approaches increase the system weight and decrease the power per unit mass provided by the battery system. Existing methods for measuring battery parameters to determine the battery state-of-health are limited. These methods include electrical measurements of the cell current and/or voltage output as well as temperature measurements taken externally on the cell surface. Such external temperature measurements are limited in their ability to provide early warning of impending battery failure. In response, an effort to develop sensors operating internal to battery for health monitoring has been ongoing in the NASA Sensor-based Prognostics to Avoid Runaway Reactions & Catastrophic Ignition (SPARRCI) project. The basic approach associated with this sensor work is the deposition of thin film sensors on the battery separator located between the anode and cathode of the battery. These thin film sensors are then monitored to determine changes in battery parameters and health. Microfabrication techniques are employed to minimize the overall impact of the sensors on battery operation through the implementation of sensors with minimal size, weight, and power consumption. The thickness of the films, which are fabricated through physical vapor deposition (sputtering), are on the order of thousands of angstroms and can have minimal surface area. Thin film sensors for system health management have been implemented for a many decades on complex components for aerospace applications. However, the application of thin films of this type on a battery separator for internal battery monitoring applications has not previously been demonstrated to our knowledge. This paper describes the development of sensors for the internal battery monitoring through the use of thin film sensor technology. Thin metal films were successfully deposited on a battery separator polymer material with good adherence and electrical continuity. Multiple types of sensors have been deposited, as well as lead connections from the sensor to the edge of the separator material. The ability of these thin film sensors immersed in electrolyte to perform multiple types of battery parameter measurements has been demonstrated. For example, a multiparameter sensor system measured multiple properties simultaneously inside of a pouch cell over a wide temperature range. Further, real time measurement of interior temperature changes in a battery pouch cell with an integrated interior temperature sensor was demonstrated. These changes include detecting a fault in the battery (shorting) in situ with rapid response time (less than a minute) corresponding to a more limited response by a temperature sensor mounted externally. Other aspects of monitoring battery health were also explored, such as real-time measurement of simulated dendrite growth/metal deposition by sensor on separator material demonstrated. Future efforts will include improvements in the durability of the sensor structure to allow introduction of the approach into standard battery fabrication techniques. Overall, this work is a step forward in providing a method to prevent catastrophic battery failures and provide a foundation for safer, lighter, and higher energy batteries for the electric aircraft industry.

thin film battery health↗

DOE OSTI2026

Hazard and risk analysis framework for nuclear power plant–based integrated energy systems

Employing integrated energy systems (IESs) with nuclear power plants (NPPs) can improve NPP utilization by leveraging dedicated thermal and electric power delivery, but it may also increase operational safety risks. This paper presents a framework to identify and quantify hazards and risks for such IESs. The framework combines accidentology to review past industrial accidents with failure modes and effects analysis (FMEA) to identify potential future incidents. Hydrogen explosion and toxic chemical release hazards are of particular concern. Explosion consequences are quantified using the Bauwens-Dorofeev (Bauwens) and trinitrotoluene equivalent mass (TNT-EM) methods, while chemical release consequences are computed using the Gaussian atmospheric dispersion method. Operational disturbances from direct electrical and thermal integration that may affect NPP safety are modeled using probabilistic risk analysis (PRA). Hazards and risks are then evaluated for regulatory compliance. The framework is applied to IESs comprising pressurized or boiling water reactors supplying three levels of thermal and electrical power to industrial customers. Case studies include high-temperature steam electrolysis hydrogen plants of varying capacities and a synthetic fuel production plant. Sensitivity analysis examines piping component failures in the PRA model as a precursor to cost estimation for thermal extraction line design. Additionally, Fussel-Vessely (FV) and risk increase importance (RII) measures identify risk-informed design improvements for the thermal extraction system. FMEA highlights hazards such as loss of offsite power, prompt loss of electrical load, loss of thermal output, and immediate steam diversion, in addition to hydrogen explosions and toxic chemical releases. Both Bauwens and TNT-EM methods suggest maintaining several hundred meters of separation between the NPP and hydrogen facility to mitigate explosion risks. PRA results show a maximum initiating event frequency increase of 1.15% and an overall risk increase of 0.28%. Importance measure analysis identifies upstream pipe leak isolation components as critical. Evaluating the results against safety regulations, it is concluded that hazards and risks can be managed to comply with regulations through risk-informed thermal and electrical connection designs, component selection, maintenance programs, and safe separation distances between NPPs and integrated industrial facilities.

08 - HYDROGEN↗

NASA NTRS1989

Advanced rechargeable sodium batteries with novel cathodes

Various high energy density rechargeable batteries are being considered for future space applications. Of these, the sodium-sulfur battery is one of the leading candidates. The primary advantage is the high energy density (760 Wh/kg theoretical). Energy densities in excess of 180 Wh/kg were realized in practical batteries. Other technological advantages include its chemical simplicity, absence of self-discharge, and long cycle life possibility. More recently, other high temperature sodium batteries have come into the spotlight. These systems can be described as follow: Na/Beta Double Prime-Al2O3/NaAlCl4/Metal Dichloride Sodium/metal dichloride systems are colloquially known as the zebra system and are currently being developed for traction and load leveling applications. The sodium-metal dichloride systems appear to offer many of the same advantages of the Na/S system, especially in terms of energy density and chemical simplicity. The metal dichloride systems offer increased safety and good resistance to overcharge and operate over a wide range of temperatures from 150 to 400 C with less corrosion problems.

Distefano, S.↗

DOE OSTI2026

Understanding Isomeric Effects on Properties of Aviation Fuels via a Group Contribution Method: Preprint

The molecular composition of aviation fuels, including conventional and sustainable aviation fuels (SAFs), significantly influences their performance, safety, and environmental impact. This study examines the effect of isomeric variation for compounds with the same carbon number and chemical family on key fuel properties, focusing on compounds commonly found in conventional jet fuels and SAFs. A group contribution method (GCM) is employed to predict thermophysical and combustion properties, providing an efficient analytical approach to evaluate the contributions of individual compounds to overall fuel mixture behavior. As part of this work, we introduce FuelLib, an open-source Python tool built around the GCM, to calculate individual compound and fuel mixture properties using various mixing rules. Our work evaluates whether the GCM can capture isomeric effects, that are often overlooked in traditional fuel property estimation. This is particularly important for SAFs, which often are composed of a more limited set of compound classes than conventional fuels, making isomeric differences more critical. Two-dimensional gas chromatography (GCxGC) data, which can be obtained from small fuel samples, provides weight percentages of compounds grouped by chemical family and carbon number rather than detailed information about individual compounds. As a result, assumptions must be made when decomposing GCxGC data into functional groups for GCM applications. Using GCxGC data, we show that the FuelLib tool can be used to predict the fuel properties of conventional jet fuels, with validation against experimental data. The provided tool enables researchers to predict fuel properties of candidate fuels and supports the design of new SAFs at both the component and mixture levels. This capability provides a foundation for studying fuel and combustion properties during SAF development, reducing reliance on costly experimental methods and advancing progress toward certification of new SAFs.The molecular composition of aviation fuels, including conventional and sustainable aviation fuels (SAFs), significantly influences their performance, safety, and environmental impact. This study examines the effect of isomeric variation for compounds with the same carbon number and chemical family on key fuel properties, focusing on compounds commonly found in conventional jet fuels and SAFs. A group contribution method (GCM) is employed to predict thermophysical and combustion properties, providing an efficient analytical approach to evaluate the contributions of individual compounds to overall fuel mixture behavior. As part of this work, we introduce FuelLib, an open-source Python tool built around the GCM, to calculate individual compound and fuel mixture properties using various mixing rules. Our work evaluates whether the GCM can capture isomeric effects, that are often overlooked in traditional fuel property estimation. This is particularly important for SAFs, which often are composed of a more limited set of compound classes than conventional fuels, making isomeric differences more critical. Two-dimensional gas chromatography (GCxGC) data, which can be obtained from small fuel samples, provides weight percentages of compounds grouped by chemical family and carbon number rather than detailed information about individual compounds. As a result, assumptions must be made when decomposing GCxGC data into functional groups for GCM applications. Using GCxGC data, we show that the FuelLib tool can be used to predict the fuel properties of conventional jet fuels, with validation against experimental data. The provided tool enables researchers to predict fuel properties of candidate fuels and supports the design of new SAFs at both the component and mixture levels. This capability provides a foundation for studying fuel and combustion properties during SAF development, reducing reliance on costly experimental methods and advancing progress toward certification of new SAFs.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1985

Reactor power system deployment and startup

This paper addresses issues that should receive further examination in the near-term as concept selection for development of a U.S. space reactor power system is approached. The issues include: the economics, practicality and system reliability associated with transfer of nuclear spacecraft from low earth shuttle orbits to operational orbits, via chemical propulsion versus nuclear electric propulsion; possible astronaut supervised reactor and nuclear electric propulsion startup in low altitude Shuttle orbit; potential deployment methods for nuclear powered spacecraft from Shuttle; the general public safety of low altitude startup and nuclear safe and disposal orbits; the question of preferred reactor power level; and the question of frozen versus molten alkali metal coolant during launch and deployment. These issues must be considered now because they impact the SP-100 concept selection, power level selection, weight and size limits, use of deployable radiators, reliability requirements, and economics, as well as the degree of need for and the urgency of developing space reactor power systems.

Wetch, J. R.↗

DOE OSTI2025

Using Best Basis Inventory Data to Direct Strategies for Real-Time Monitoring of Hanford High Level Waste

The proposed Direct Feed High Level Waste (DFHLW) approach for processing high-level tank waste at Hanford is intended to reduce processing time by bypassing the Pretreatment Facility and transferring waste directly from the tank farm to the WTP HLW vitrification facility. This processing strategy could reduce or eliminate the washing and leaching steps that would have occurred in the Pretreatment facility. Operation of the vitrification facility is subject to chemical and radiological limits protecting safety (e.g. Waste Acceptance Criteria, or WACs) and process quality (e.g. Process Control Limits, or PCLs). Without washing and leaching, there is a greater risk of exceeding the WACs and PCLs. Hanford process engineers have devised blending strategies based on known chemical and radiological composition, volumes, and solids loadings of individual layers within each waste tank. These blending campaigns succeed in predicting a processing strategy that does not exceed the WACs and PCLs. However, the calculations do not ascribe uncertainties to the tank analysis data, quantities of material taken from the tanks to make the blend, or potential for mixing of layers within tanks. In order to confirm that a process strategy is working, it would be advantageous to have inline or at-line analytical instrumentation installed in the processing facilities that deliver measurement results in real time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1991

Concepts of bioisolation for life sciences research on Space Station Freedom

The risk concepts related to biological research in space are defined with attention given to the design and operation of experimental hardware for NASA's Biological Flight Research Laboratory (BFRL). The definitions are set forth to describe safety measures for the use of nonhuman specimens in microgravity environments and the direct application of the risk-control concepts. Bioisolation is the process by which biological systems can coexist productively by means of physical, chemical, or biological methods; bioisolation requirements are given for mammals, plants, and microspecimens. The BRFL provides two levels of containment based on the complete sealing of all joints and interfaces in the Modular Habitat and an airflow system designed to provide net negative pressure of at least 0.13 kPa. The requirements are designed to assure a safe working environment for conducting nonhuman life-sciences research in the Space Station Freedom.

Funk, Glenn A.↗

DOE OSTI2026

Modeling glass degradation and release of radionuclides from vitrified waste for performance assessment simulations

The release of radionuclides initially encapsulated in a slowly degrading solid waste form and contained in an eventually corroding canister defines the source term for numerical simulations for the assessment of a geologic repository for high-level radioactive waste. While the details of waste degradation, canister corrosion, and dissolution and mobilization of the radionuclides in pore water include complex chemical reaction and transport processes that are coupled to the thermal, hydrological, microbiological, and mechanical conditions in the repository, the source-term model suitable for use in a numerical performance assessment model should be a defensible abstraction of these mechanisms. We developed a radiological source-term model and implemented it into a non-isothermal flow and transport simulator. While the proposed source-term model is applicable to various waste forms, canister systems, and disposal concepts, we specifically considered radionuclide releases from vitrified high-level waste placed in a cylindrical canister disposed in a deep vertical borehole repository. In this model, waste degradation is a function of temperature, and it can be adjusted to evaluate the influence of and propagate uncertainties in pH, passivation reactions, and chemical conditions as well as geometrical factors. The time-dependent, congruent release of safety-relevant radionuclides present in the decaying inventory is then calculated. Finally, the radionuclides are mobilized by diffusive and advective transport according to the thermo-hydraulic conditions prevailing in the near field of the repository, from where they migrate through the geosphere to the accessible environment. We examine the influence of the source-term model’s parameters on performance assessment calculations through sensitivity and uncertainty propagation analyses, identifying influential factors and confirming the upper bound of their impact. These considerations align with the overarching goal of repository design, which is to demonstrate that engineered and natural barriers can collectively delay radionuclide migration for timescales far exceeding human planning, thereby providing multiple, redundant barriers against environmental contamination.

iTOUGH2↗

DOE OSTI2026

Charged Defects in UO 2 Bulk and Surface: A First-Principles Study

Uranium dioxide (UO 2 ) is the primary fuel used in nuclear reactors. Under the extreme heat and radiation inside a reactor, this material inevitably develops defects in its crystal structure. To investigate the nature and behavior of these defects, DFT+U calculations were employed to investigate charged point defects in both bulk UO 2 and its most stable surface, the (111) plane. The formation of defects and their impact on the electronic structure were systematically examined. The results reveal that these defects introduce localized electronic states, alter magnetic behavior, and modify the structural properties. In general, such defects act as deep traps capable of capturing and retaining charge carriers. The stability of these defects depends strongly on the chemical environment and the position of the Fermi level. Surface defect calculations reveal that oxygen vacancies form more readily at the surface than in the bulk over a wide range of electron chemical potential, with subsurface oxygen vacancies being more stable than those in the top layer. Overall, the findings demonstrate how charged defects influence magnetism, transport, and stability in UO 2 , providing insights that may guide improvements in the safety and efficiency of nuclear fuel.

36 MATERIALS SCIENCE↗

NASA NTRS1989

The Space Station Freedom - International cooperation and innovation in space safety

The Space Station Freedom (SSF) being developed by the United States, European Space Agency (ESA), Japan, and Canada poses novel safety challenges in design, operations, logistics, and program management. A brief overview discloses many features that make SSF a radical departure from earlier low earth orbit (LEO) space stations relative to safety management: size and power levels; multiphase manned assembly; 30-year planned lifetime, with embedded 'hooks and scars' forevolution; crew size and skill-mix variability; sustained logistical dependence; use of man, robotics and telepresence for on-orbit maintenance of station and free-flyer systems; closed-environment recycling; use of automation and expert systems; long-term operation of collocated life-sciences and materials-science experiments, requiring control and segregation of hazardous and chemically incompatible materials; and materials aging in space.

Rodney, George A.↗

DOE OSTI2024

RANGERS: Modeling Report on Integrity and Performance Assessment of Engineered Barrier Systems in a Salt Repository for HLW/SNF

The Engineered Barrier System (EBS) plays an important role in ensuring the long-term safety and containment of high-level waste (HLW) and spent nuclear fuel (SNF) in deep geological repositories in salt formation. As part of a multi-barrier system, the EBS works alongside the natural barrier, which is the salt formation itself and the technical barrier comprising the disposal casks. The primary function of the EBS is to maintain containment during a defined period until the backfill used in the repository made of crushed salt, develops its sealing capacity through compaction. Over the time, the backfill eventually compacts to a state of low porosity and permeability, acting as a long-term seal. However, until this process is complete, the EBS must retain its structural and functional integrity. Regulatory guidelines in Germany currently require the EBS to remain effective for up to next ice age, that is expected in 50,000 years. The significant hydro-geological and topographic changes expected during an ice age could make it impossible to accurately predict the hydro-chemical conditions within the repository system at that time. In response to these challenges, BGE TECHNOLOGY GmbH (BGE TEC) and Sandia National Laboratories (SNL) have jointly developed a comprehensive methodology for the design and safety assessment of engineered barrier systems within the scope of the RANGERS project. This methodology is tailored for repositories in salt formations. The developed methodology provides a structured approach for designing and assessing the performance of the EBS in salt-based repositories. It begins with defining a sealing concept based on the geological characteristics of the selected site and the overall repository design. The entire repository system, comprising the geological site, repository infrastructure, and EBS, is then subjected to a Features, Events, and Processes (FEP) analysis, focusing solely on those FEPs that affect the EBS. The derived FEPs help identify the loads and stresses acting on the EBS, which serve as the foundation for conducting an integrity assessment. This analysis helps predict the EBS’s evolution and performance over the regulatory time frame, feeding into integrated performance assessment simulations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1976

An Investigation of Size-Dependent Concentration of Trace Elements in Aerosols Emitted from the Oil-Fired Heating Plants

Aerosols emitted from two oil-fired heating plants were aerodynamically separated into eight size groups and were analyzed using the photon-induced X-ray emission (PIXE) technique. It was found that Zn, Mo, Ag, and Pb, and (to a lesser extent) Cd, have a tendency to concentrate preferentially on the smaller aerosols. All of these elements, in certain chemical forms, are known to be toxic. Zinc and molybdenum, although present in low concentrations in the parent fuels, show the strongest tendencies to be concentrated in finer aerosols. Selenium, previously reported to show a very strong tendency to concentration in finer fly ash from coal-fired power plants shows little preference for surface residence. Vanadium, which occurs in significant concentration in the oil fuels for both plants, also shows little preference for surface concentration. Even though the absolute concentrations of the toxic elements involved are well below the safety levels established by the National Institute for Occupational Safety and Health (NIOSH), it would be advisable to raise the heights of the heating-plant exhaust chimneys well above the neighborhood buildings to insure more efficient aerosol dispersal.

Singh, J. J.↗

NASA NTRS1989

Environmental Projects. Volume 8: Modifications of wastewater evaporation ponds

The Goldstone Deep Space Communications Complex (GDSCC), located in the Mojave Desert about 45 miles north of Barstow, California, and about 160 miles northeast of Pasadena, is part of NASA's Deep Space Network, one of the world's largest and most sensitive scientific telecommunications and radio navigation networks. The Goldstone Complex is managed, technically directed, and operated for NASA by the Jet Propulsion Laboratory (JPL) of the California Institute of Technology in Pasadena, California. Activities at the GDSCC are carried out in support of seven parabolic dish antennas. These activities may give rise to environmental hazards: use of hazardous chemicals, asbestos, and underground storage tanks as well as the generation of hazardous wastes and the disposal of wastewater. Federal, state, and local laws governing the management of hazardous substances, asbestos, underground storage tanks and wastewater disposal have become so complex there is a need to devise specific programs to comply with the many regulations that implement these laws. In support of the national goal of the preservation of the environment and the protection of human health and safety, NASA, JPL, and the GDSCC have adopted a position that their operating installations shall maintain a high level of compliance with these laws. One of the environmental problems at the GDSCC involved four active, operational, wastewater evaporation ponds designed to receive and evaporate sewage effluent from upstream septic tank systems. One pair of active wastewater evaporation ponds is located at Echo Site, while another operational pair is at Mars Site.

Source record↗

NASA NTRS1972

Mercury contamination study for flight system safety

The effects and prevention of possible mercury pollution from the failure of solar electric propulsion spacecraft using mercury propellant were studied from tankage loading of post launch trajector injection. During preflight operations and initial flight mode there is little danger of mercury pollution if proper safety precautions are taken. Any spillage on the loading, mating, transportation, or launch pad areas is obvious and can be removed by vacuum cleaning soil and chemical fixing. Mercury spilled on Cape Kennedy ground soil will be chemically complexed and retained by the sandstone subsoil. A cover layer of sand or gravel on spilled mercury which has settled to the bottom of a water body adjacent to the system operation will control and eliminate the formation of toxic organic mercurials. Mercury released into the earth's atmosphere through leakage of a fireball will be diffused to low concentration levels. However, gas phase reactions of mercury with ozone could cause a local ozone depletion and result in serious ecological hazards.

Gorzynski, C. S., Jr.↗

DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗

DOE OSTI2025

Domestic and International Consensus Standards for Nuclear Criticality Safety - Overview & Status

The domestic and international consensus standards for nuclear criticality safety (NCS) were developed based on the lessons-learned from process criticality accidents. These consensus standards were developed to reduce the rate of process criticality accidents in facilities that process, store, handle, or transport fissionable materials by hand. After a significant increase in criticality accidents through the mid-1960s, the rate of criticality accidents decreased as a result of these standards, and the criticality accident rate is extremely low from an industrial safety perspective. The last known criticality accident inside the United States was in 1978 (nearly 47 years ago) at the Idaho Chemical Processing Plant, and outside the United States, an accident occurred at Tokai-mura, Japan, in 1999 (almost 26 years ago). The domestic consensus standards for NCS include the American National Standards (ANS) that are prepared and published by the American Nuclear Society and approved by the American National Standards Institute (ANSI). The ANS Standards Board, the NCS Consensus Committee, and the ANS-8 Subcommittee oversee the development and maintenance of these standards. There are currently 18 standards in the ANS-8 series. Nine ANS-8 standards are either in revision mode or planned for revision. A new standard for the use of nondestructive assay measurements (ANSI/ANS-8.28-2024) for NCS was approved in March of 2024. The international consensus standards for NCS calculations, procedures, and practices are maintained and developed within the International Organization for Standardization, Technical Committee 85 “Nuclear Energy,” Subcommittee 5, “Nuclear Fuel Technology,” and Working Group 8, “Nuclear Criticality Safety.” Eleven standards are currently available, four standards are proposed for revision, and four standards are at various stages of development. This paper provides the NCS community with a high-level overview and status report of domestic and international NCS consensus standards to stimulate interest and to support their continued development.

Bowen, Douglas G [ORNL] (ORCID:0000000212460026)↗