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Quality Guidelines for Energy System Studies: Cost Estimation Methodology for NETL Techno-economic Assessments

This Quality Guidelines for Energy System Studies (QGESS) summarizes the methodology employed by the National Energy Technology Laboratory (NETL) in calculating plant costs in its techno-economic studies, such as the Cost and Performance Baseline for Fossil Energy Systems series of reports. It also outlines the approach used to calculate the cost of electricity (COE) or cost of product (COP) metrics by which NETL estimates the impact of technology options. These metrics and a clear understanding of the methodology used are essential in allowing different plant technologies to be compared on a similar basis. These guidelines were initially developed for power producing plants, although they can be applied to a variety of different revenue generating plants (e.g., coal to liquids, syngas generation, hydrogen) by substituting the industrial product quantity for the electrical quantity in the equations. The tables contained in this QGESS have been expanded upon relative to previous versions to include values to assume for several industries.

20 FOSSIL-FUELED POWER PLANTS

Quality Guidelines for Energy System Studies: Process Modeling Design Parameters

The National Energy Technology Laboratory (NETL) conducts systems analysis studies that require a large number of inputs, from ambient conditions to parameters for Aspen Plus ® (Aspen) process blocks. The sheer number of assumptions required makes it impractical to document all of them in each issued report. The purpose of the Quality Guidelines for Energy System Studies (QGESS) is to document the assumptions most commonly used in system analysis studies and the basis for those assumptions. In order to develop the systems analysis models presented in various NETL reports, significant vendor data have been obtained, and these data enhance the model outputs. Much of the vendor data obtained are considered proprietary and not suitable for public release or attribution to a specific vendor. As such, several sub-systems common in NETL reports and their process parameter data are not reported in this document to protect proprietary vendor information. The values and ranges of values presented in this report represent assumptions that have been made in previous studies.

97 MATHEMATICS AND COMPUTING

Quality Guidelines for Energy System Studies: Capital Cost Scaling Methodology: Revision 4b Report

The National Energy Technology Laboratory (NETL) regularly updates legacy analysis with new studies and cases as the Department of Energy objectives change, technology performance improves, costs are reduced, regulations change, market drivers are established, fuel prices fluctuate, and any number of other relevant factors vary in the market. As legacy studies are updated by NETL, the underlying performance and cost of the cases presented changes, and as such, the methods for interpreting and scaling the cost estimates change. Therefore, it is important that NETL maintain public guidance documents associated with different sets of cost estimates that delineate how a specific set, based on report vintage and/or year published, should be scaled. This Quality Guidelines for Energy System Studies report, providing guidance on capital cost scaling, should generally be applied to NETL case costs included in the report “Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity Revision 4b,” (NETL, 2025) or any cases derived from the cases presented in the referenced report.

29 ENERGY PLANNING, POLICY, AND ECONOMY

Quality assurance program guidelines for application to and use by manufacturers of rail/guideway vehicles, buses, automatic train control systems, and their major subsystems

Guidelines are presented for a quality assurance system to be implemented by the manufacturer in support of designing, developing, fabricating, assembling, inspecting, testing, handling, and delivery of equipment being procured for use in public urban mass transit systems. The guidelines apply to this equipment when being procured for: (1) use in revenue service; (2) demonstration of systems that will be revenue producing or used by the public; (3) use as a prototype for follow-on operational/revenue producing equipment procurements; and (4) qualification tests.

Witkin, S. A.

Evaluation and calibration of MERRA-2 and CAMS reanalysis for PM 2.5 in a semi-urbanized area in the south of the Amazon

Air pollution has significant implications for the climate and poses irreversible risks to human health. The Amazon region of Brazil is severely affected by biomass burning (BB) emissions, yet air quality monitoring remains highly inadequate. Given the scarcity of surface-based observations, reanalysis models have become essential tools for assessing air pollution. Although MERRA-2 and CAMS PM 2.5 products are widely utilized, their validation and comprehensive evaluation for the Amazon Basin remain limited. Here, this study assesses the performance of these products in a semi-urbanized region in the southern Amazon. The calibrated time series was employed to analyze PM 2.5 concentrations from 2003 to 2023. Our results showed satisfactory performance of both products for the 24-h averages of PM 2.5 , with linear correlations above 0.76. However, it was found that both products overestimate surface concentrations. MERRA-2 performed better, with approximately 30% lower bias than CAMS. Time series analysis showed that the study area is strongly impacted by emissions BB in the dry period, mainly in August and September. Furthermore, our findings indicate a positive trend in increasing PM 2.5 concentrations, with a notable rise observed since 2014. The average PM 2.5 levels frequently exceed the daily air quality guidelines established by the WHO in 2021. It has been estimated that the population of this region is exposed to concentrations above 15 μg.m -3 , on average, more than 30 days per year. Our results contribute to the evaluation of MERRA-2 and CAMS products for Amazon and provide a corrected estimate for surface PM 2.5 . Recent concerns about air quality and the implementation of new surface monitoring networks may improve the evaluation of reanalysis products. In the short term, the need for this information makes our assessments indispensable.

54 ENVIRONMENTAL SCIENCES

Remote sensing in the mixing zone

Characteristics of dispersion and diffusion as the mechanisms by which pollutants are transported in natural river courses were studied with the view of providing additional data for the establishment of water quality guidelines and effluent outfall design protocols. Work has been divided into four basic categories which are directed at the basic goal of developing relationships which will permit the estimation of the nature and extent of the mixing zone as a function of those variables which characterize the outfall structure, the effluent, and the river, as well as climatological conditions. The four basic categories of effort are: (1) the development of mathematical models; (2) laboratory studies of physical models; (3) field surveys involving ground and aerial sensing; and (4) correlation between aerial photographic imagery and mixing zone characteristics.

Villemonte, J. R.

Photographic quantification of water quality in mixing zones

A method was developed to quantitatively delineate waste concentrations throughout waste effluent mixing zones on the basis of densitometric measurements extracted from aerial photography. A mixing zone is the extent of a receiving water body ultilized to dilute a waste discharge to a concentration characteristic of a totally mixed condition. Simultaneously-acquired color infrared photography and suspended solids water samples were used to quantitatively delineate the mixing zone resulting from the discharge of a paper mill effluent. Digital scanning microdensitometer data was used to estimate and delineate suspended solids concentrations on the basis of a semi-empirical model. Photographic photometry, when predicated on a limited amount of ground sampling, can measure and delineate mixing zone waste distributions in more detail then conventional surface measuring techniques. The method has direct application to: (1) the establishment of definite and rational water quality guidelines; (2) the development of sampling and surveillance programs for use by governmental and private agencies; and (3) the development of design and location criteria for industrial and municipal waste effluent outfalls.

Lillesand, T. M.

Remote sensing in the mixing zone

Results to date of a study of the dispersion and diffusion mechanisms by which pollutants are transported in natural river courses. The mixing zone at several industrial sites was studied by both ground and remote sensing methods. The advantage of coordination of these two methods is highlighted. The results can be used in the establishment of definite and rational water quality guidelines and in the development of a sampling and surveillance program by governmental and private agencies.

Villemonte, J. R.

Photographic quantification of water quality in mixing zones

The waste effluent mixing zone is defined as the extent of a receiving water body utilized to dilute a waste charge to a concentration characteristic of a totally mixed condition. Color IR photography was used in conjunction with suspended solids water samples to quantitatively delineate the mixing zone resulting from the discharge of a paper mill effluent. Digital scanning microdensitometer data were used to estimate and delineate suspended solids concentrations on the basis of a semiempirical model. Model background, development, and implementation are described. Results indicate that the method is as reliable as conventional surface measuring techniques and is, in fact, more detailed. The method has direct application to the establishment of water quality guidelines, the development of both governmental and private sampling and surveillance programs, and the development of design and location criteria for industrial and municipal waste effluent outfalls.

Lillesand, T. M.

Summary of development and recommendations for a quality assurance program for the procurement and manufacture of urban mass transit operating equipment and systems

A viable quality program for the urban mass transit industry, and a management approach to ensure compliance with the program are outlined. Included are: (1) a set of guidelines for quality assurance to be imposed on transit authorities, and a management approach to ensure compliance with them; (2) a management approach to be used by the transit authorities (properties) for assuring compliance with the QA guidelines; and (3) quality assurance guidelines to be imposed by properties and umta for procurement of hardware and systems.

Witkin, S. A.

Safety, reliability, maintainability and quality provisions for the Space Shuttle program

This publication establishes common safety, reliability, maintainability and quality provisions for the Space Shuttle Program. NASA Centers shall use this publication both as the basis for negotiating safety, reliability, maintainability and quality requirements with Shuttle Program contractors and as the guideline for conduct of program safety, reliability, maintainability and quality activities at the Centers. Centers shall assure that applicable provisions of the publication are imposed in lower tier contracts. Centers shall give due regard to other Space Shuttle Program planning in order to provide an integrated total Space Shuttle Program activity. In the implementation of safety, reliability, maintainability and quality activities, consideration shall be given to hardware complexity, supplier experience, state of hardware development, unit cost, and hardware use. The approach and methods for contractor implementation shall be described in the contractors safety, reliability, maintainability and quality plans. This publication incorporates provisions of NASA documents: NHB 1700.1 'NASA Safety Manual, Vol. 1'; NHB 5300.4(IA), 'Reliability Program Provisions for Aeronautical and Space System Contractors'; and NHB 5300.4(1B), 'Quality Program Provisions for Aeronautical and Space System Contractors'. It has been tailored from the above documents based on experience in other programs. It is intended that this publication be reviewed and revised, as appropriate, to reflect new experience and to assure continuing viability.

M S Malkin

Liquid and gaseous oxygen safety review

Materials used in oxygen systems and allowable oxygen environments are specified for each material. Design criteria, cleaning procedures and quality control methods are covered. Guidelines for protection against hazards involved with production, transportation, storage and use of oxygen are presented. Study also lists extensive references.

Lapin, A.

Investigation of electroforming techniques

Copper and nickel electroforming was examined for the purpose of establishing the necessary processes and procedures for repeatable, successful fabrication of the outer structures of regeneratively cooled thrust chambers. The selection of electrolytes for copper and nickel deposition is described. The development studies performed to refine and complete the processes necessary for successful chamber shell fabrication and the testing employed to verify the applicability of the processes and procedures to small scale hardware are described. Specifications were developed to afford a guideline for the electroforming of high quality outer shells on regeneratively cooled thrust chamber liners. Test results indicated repeatable mechanical properties could be produced in copper deposits from the copper sulfate electrolyte with periodic current reversal and in nickel deposits from the sulfamate solution. Use of inert, removable channel fillers and the conductivizing of such is described. Techniques (verified by test) which produce high integrity bonds to copper and copper alloy liners are discussed.

Malone, G. A.

ORNL Package Testing Program Software Quality Assurance Plan

The Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP) uses commercial off-the-shelf (COTS) software in performing data collection of thermal test results for package designs that contain radioactive materials. Specifically, this software is used to collect temperature data from the furnace, packages, and ambient air to prepare and execute the thermal test specified in 10 CFR 71.73, “Thermal Test.” This software quality assurance (SQA) plan sets forth the guidelines, standards, and procedures that shall be used to provide SQA for PTP software applications. This is a living document that will be maintained for the lifecycle of the PTP program. The SQA plan follows the requirements set forth in ORNL Standards Based Management System (SBMS): Information Technology; Subject Area: Software Quality Assurance. When applicable to the requirements as described in ORNL SBMS, Software Quality Assurance, the software shall be listed in the ORNL Software Registration System (SRS). Exemptions to this SBMS are COTS and firmware that are not modified; spreadsheet applications and personal productivity tools that do not have a utility or safety application, research applications, legacy software, system software, vendor-supplied software used to interface with the vendor’s services, software used within the organization to facilitate processing or management of information, and software developed for applications not specific to the US Department of Energy (DOE).

97 MATHEMATICS AND COMPUTING