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ARPA-E Program: Advanced Management Protection of Energy Storage Devices (AMPED) - Monthly Report - November 2013

Technology has been developed that enables monitoring of individual cells in high - capacity lithium-ion battery packs, with a distributed array of wireless Bluetooth 4.0 tags and sensors, and without proliferation of extensive wiring harnesses. Given the safety challenges facing lithium-ion batteries in electric vehicle, civilian aviation and defense applications, these wireless sensors may be particularly important to these emerging markets. These wireless sensors will enhance the performance, reliability and safety of such energy storage systems. Specific accomplishments to date include, but are not limited to: (1) the development of wireless tags using Bluetooth 4.0 standard to monitor a large array of sensors in battery pack; (2) sensor suites enabling the simultaneous monitoring of cell voltage, cell current, cell temperature, and package strain, indicative of swelling and increased internal pressure, (3) small receivers compatible with USB ports on portable computers; (4) software drivers and logging software; (5) a 7S2P battery simulator, enabling the safe development of wireless BMS hardware in the laboratory; (6) demonstrated data transmission out of metal enclosures, including battery box, with small variable aperture opening; (7) test data demonstrating the accurate and reliable operation of sensors, with transmission of terminal voltage, cell temperature and package strain at distances up to 110 feet; (8) quantification of the data transmission error as a function of distance, in both indoor and outdoor operation; (9) electromagnetic interference testing during operation with live, high -capacity battery management system at Yardney Technical Products; (10) demonstrat ed operation with live high-capacity lithium-ion battery pack during charge-discharge cycling; (11) development of special polymer-gel lithium-ion batteries with embedded temperature sensors, capable of measuring the core temperature of individual of the cells during charge-discharge cycling at various temperatures, thereby enabling earlier warning of thermal runaway than possible with external sensors. Ultimately, the team plans to extend this work to include: (12) flexible wireless controllers, also using Bluetooth 4.0 standard, essential for balancing large-scale battery packs. LLNL received $925K for this project, and has $191K remaining after accomplishing these objectives.

25 ENERGY STORAGE↗

Novel Battery Management System with Distributed Wireless and Fiber Optic Sensors for Early Detection and Suppression of Thermal Runaway in Large Battery Packs, FY13 Q4 Report, ARPA-E Program: Advanced Management Protection of Energy Storage Devices (AMPE

Technology has been developed that enables monitoring of individual cells in highcapacity lithium-ion battery packs, with a distributed array of wireless Bluetooth 4.0 tags and sensors, and without proliferation of extensive wiring harnesses. Given the safety challenges facing lithium-ion batteries in electric vehicle, civilian aviation and defense applications, these wireless sensors may be particularly important to these emerging markets. These wireless sensors will enhance the performance, reliability and safety of such energy storage systems. Specific accomplishments to date include, but are not limited to: (1) the development of wireless tags using Bluetooth 4.0 standard to monitor a large array of sensors in battery pack; (2) sensor suites enabling the simultaneous monitoring of cell voltage, cell current, cell temperature, and package strain, indicative of swelling and increased internal pressure, (3) small receivers compatible with USB ports on portable computers; (4) software drivers and logging software; (5) a 7S2P battery simulator, enabling the safe development of wireless BMS hardware in the laboratory; (6) demonstrated data transmission out of metal enclosures, including battery box, with small variable aperture opening; (7) test data demonstrating the accurate and reliable operation of sensors, with transmission of terminal voltage, cell temperature and package strain at distances up to 110 feet; (8) quantification of the data transmission error as a function of distance, in both indoor and outdoor operation; (9) electromagnetic interference testing during operation with live, high-capacity battery management system at Yardney Technical Products; (10) demonstrated operation with live high-capacity lithium-ion battery pack during charge-discharge cycling; (11) development of special polymer-gel lithium-ion batteries with embedded temperature sensors, capable of measuring the core temperature of individual of the cells during charge-discharge cycling at various temperatures, thereby enabling earlier warning of thermal runaway than possible with external sensors. Ultimately, the team plans to extend this work to include: (12) flexible wireless controllers, also using Bluetooth 4.0 standard, essential for balancing large-scale battery packs. LLNL received $925K for this project, and has $191K remaining after accomplishing these objectives.

25 ENERGY STORAGE↗

Using Charge-Coupled Devices to Characterize Neutron Events

Ultra-cold neutrons (UCNs) are free neutrons with less than 300 neV of kinetic energy. UCNs are useful for studying position-dependent quantum states, as they are only influenced by Earth’s gravity. Precise measurements of these quantum states can give great insight into dark matter, dark energy, and quantum gravity. We have been calibrating and testing a charge-coupled device (CCD) so that it can be coated with boron-10 to track the reaction products produced between the boron and UCNs. Additionally, we have been using a simulation software package called The Stopping and Range of Ions in Matter (SRIM), which uses Monte Carlo methods to track ions in a chosen target. This package is useful to find a correlation between incident ion angles and 2D variance of the CCD hit.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Validation and Verification for INL Modelica-based TEDS models Via Experimental Results

This report provides an overview on the verification and validation (V&V) of the Thermal Energy Distribution System (TEDS) model developed in the Modelica process modeling ecosystem using experimental data. Model development has led to the creation of a dynamic process model of the experimental TEDS facility housed within the Energy Systems Laboratory (ESL) at Idaho National Laboratory (INL). The model was then used during the preconstruction phase of the experimental effort to inform experimental design (e.g., insulation requirements, bypass line placement, expected performance of components) and to test innovative control schemes prior to the initial operation. The TEDS model developed in Modelica includes the primary components of the TEDS experimental unit: a 200kW Chromalox heater; a single-tank packed-bed thermal energy storage system filled with 0.125-inch alumina (Al2O3) beads; an ethylene-glycol-to-Therminol-66 heat exchanger; system piping; five control valves; and all associated temperature, pressure, and volumetric flow sensors. Using the Institute of Electrical and Electronics Engineers (IEEE) V&V methodologies, considered the gold standard in the engineering field, the model was verified using a combination of static analysis, spatial convergence, and regression tests. Then using dynamic time warping (DTW) initial runs to validate and tune the TEDS model versus the experiment were conducted. This tuning method was accomplished using the INL Risk Analysis Virtual ENvironment (RAVEN) software package. Tuning is required to account for physical phenomena that are less understood within the empirical heat transfer correlations. Through the commencement of this work, a systems-level model of TEDS with associated control systems, sensors, piping diameters, and component capabilities has been created. This model was utilized in the pre-experimental phase to inform system design, insulation thicknesses, and potential control schemes to operate the system effectively and safely. Then, initial experimental startup and operational data were used to demonstrate the validation and tuning methodology. This process demonstrates the classical two-step approach of a model informing experimental design followed by the experiment validation and tuning the model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

AniMACCS User Guide

This SAND Report provides an overview of AniMACCS, the animation software developed for the MELCOR Accident Consequence Code System (MACCS). It details what users need to know in order to successfully generate animations from MACCS results. It also includes information on the capabilities, requirements, testing, limitations, input settings, and problem reporting instructions for AniMACCS version 1.3.1. Supporting information is provided in the appendices, such as guidance on required input files using both WinMACCS and running MACCS from the command line.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

Innovative Strategies for Long-Term Monitoring of Complex Groundwater Plumes at DOE’s Legacy Sites (Workshop Report)

Most remaining Department of Energy (DOE) sites will require extended periods of institutional control, especially at complex groundwater sites where attenuation-based strategies have been implemented to facilitate closure. The current practice of monitoring—obtaining and analyzing contaminant concentration in groundwater samples at numerous wells—will account for a large portion of the projected life-cycle at these DOE sites unless a new approach is adopted. State-of-the-art technologies are being developed, including in situ sensors, geophysics, radiation mapping, numerical modeling and AI/ML. These technologies can optimize monitoring strategies in space and time, provide spatially extensive information at vulnerable regions and/or provide more continuous monitoring at lower cost. As part of DOE’s Office of Environmental Management (DOE-EM’s) efforts to advance long-term monitoring systems, an in-person/virtual hybrid workshop was hosted by Savannah River National Laboratory (SRNL) on January 24 and 25, 2023, in Augusta, Georgia. Because DOE-EM’s complex sites will eventually be transferred to DOE’s Office of Legacy Management (DOE-LM), representatives of DOE-LM were important participants in the workshop. The purpose of the workshop was to identify challenges and opportunities for deploying advanced technologies for long-term monitoring at DOE sites. The key questions during the workshop were: 1) the regulatory acceptance of replacing a process that traditionally has used laboratory sampling and analysis of groundwater samples, and 2) the application of this strategy to the southwestern arid sites that include many of the remaining DOE-EM and DOE-LM complex groundwater plumes. Characteristics common to most arid sites present both limitations and opportunities for advanced technologies. DOE-EM has funded a National Laboratory team from SRNL, Lawrence Berkeley National Laboratory (LBNL), and Pacific Northwest National Laboratory (PNNL) to establish the overarching framework of long-term monitoring by systematically combining advanced hardware and software technologies. This project is titled “Advanced Long-Term Environmental Monitoring Systems (ALTEMIS)” and is sponsored by the DOE-EM Technology Development Program. The multi-laboratory team is currently developing and testing innovative monitoring strategies, including the use of in situ groundwater sensors, geophysics, drone/satellite-based remote sensing, reactive transport modeling, and artificial intelligence/machine learning (AI/ML). The project’s demonstration testbed is at the Savannah River Site (SRS) F-Area Seepage Basins, where a well-characterized complex groundwater plume composed of uranium and other radionuclides is in the latter stages of remediation. The workshop included more than 70 participants, presentations, a field visit to F-Area, breakout working groups, and large group discussion. Participants developed recommendations on five topics: in situ sensors, spatially integrative tools, challenges to regulatory acceptance, AI/ML strategies, and transitioning sites to DOE-LM.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Technology & Design Innovations to Maximize the Reduction Effect on DCFC Unit Cost Economics (Max‐REDUCE)

With the high cost and reliability issues of DCFC infrastructure the project specifically addressed the needs of innovating on the AC to DC power conversion. We proved the integration of a new power module into existing charger units, and that theoretical educational work on single stage energy conversion is commercially viable, and a reduced cost compared to existing methods. Our A sample shown 3 PH 480VAC 60hz to 350VDC 8.5kW power transfer, and our software and simulation proved efficiency greater than 97% from 20kW to > 60kW, over the DC output voltage range 200 – 1200V. The project was stopped before we could implement B sample and execute full power testing, validation and integration into a demonstration charger (budget period 3).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A Functional Test Platform for the Community Land Model

A functional test platform is presented to create direct linkages between site measurements and the process-based ecosystem model within the Community Earth System Models (CESM). The platform consists of three major parts: 1) interactive user interfaces, 2) functional test model and 3) observational datasets. It provides much needed integration interfaces for both field experimentalists and ecosystem modelers to improve the model s representation of ecosystem processes within the CESM framework without large software overhead.

Xu, Yang↗

A Tool for Longitudinal Beam Dynamics in Synchrotrons

A number of codes are available to simulate longitudinal dynamics in synchrotrons. Some established ones include TIBETAN, LONG1D, ESME and ORBIT. While they embody a wealth of accumulated wisdom and experience, most of these codes were written decades ago and to some extent they reflect the constraints of their time. As a result, there is an interest for updated tools taking better advantage of modern software and hardware capabilities. At Fermilab, the PIP-II project has provided the impetus for development of such a tool. In this contribution, we discuss design decisions and code architecture. A selection of test cases based on an initial prototype are also presented.

43 PARTICLE ACCELERATORS↗

Validation of Oregon State University High Temperature Test Facility Experiments Using Pronghorn

The OSU High Temperature Test Facility is a quarter-scale diameter, 1/64 scale volume test facility meant to replicate thermophysical phenomena in the prototypical General Atomics Modular High Temperature Gas Reactor. Tests pertaining to conduction cooldown events were performed from 2016-2019, providing a large database by which computational methods that are applicable to different length scales can be validated. One of these codes is Pronghorn, which is a coarse-meshed, porous-based subchannel thermal hydraulics code based on the MOOSE application, with the intention of better capturing the physics of both conduction and convection heat transfer within the OSU HTTF core. The goal of this summer project is to develop the framework by which Pronghorn can perform validation exercises of the HTTF core for benchmarking, by generating a mesh appropriate to the geometry of the HTTF core, developing input decks that accurately capture the initial and boundary conditions, materials, and relevant equations to the physics seen in the HTTF core, and using a postprocessor to compare simulation results to various experimental data. While validation of codes is a multi-year project, a mesh has been generated and tested in Pronghorn that meets mass conservation and basic heat transfer principles. The next step is to accurate depict the fluid inlet and outlet boundary conditions, which will be performed using computational fluid dynamics software.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

LEED: A Lightwave Energy-Efficient Datacenter

The Lightwave Energy-Efficient Datacenter (LEED) program is a disruptive “green-field” approach that provides a quantum leap in the energy efficiency of datacenters. LEED’s fundamental value proposition is that a novel and re-architected optical network—RotorNet— can deliver “more bandwidth per buck” as well as unique system-level attributes that significantly improve overall datacenter energy efficiency and performance. LEED has developed three system-level testbeds. The first testbed uses calibrated hardware and software power measurements to determine server energy efficiency as a function of network bandwidth and workload. These measurements have shown that increasing network communications bandwidth dramatically increases server energy efficiency providing a realistic path to the overall ENLITENED program goal of doubling the number of transactions per joule. The second testbed demonstrates key hardware: a prototype low-loss, high-port count optical “selector switch”. This switch was fabricated, racked, and tested. Measured switch characteristics include loss, bandwidth, crosstalk, switch time, system-level switch time (including the transceivers), and bit error rate. The third testbed demonstrates a fully working and manufactured pinwheel design which dramatically lowers the cost of design, while delivering high switch radix and low reconfiguration times. The LEED project has tied these three novel photonic switch prototypes together with production servers and software through the development of a novel FPGA-based NIC platform called Corundum. Corundum ensures that the packet-switched protocols supported by commodity operating systems and devices can interface with the Rotor switch design. The LEED group has used this combined hardware and software prototype to characterize applications running at a commercially relevant scale. The project has used a combination of enhanced optical modulation amplitude (OMA) modulators, broadband multiplexers and demultiplexers, avalanche photodiodes, and a novel burst-mode receivers to enable the insertion of LEED-developed optical switches without the need for expensive optical amplification. Our modeling has shown that measured LEED-developed device characteristics can achieve link characteristics of 2 pJ/bit including both transceivers and the Rotor switch. In summary, the LEED program has demonstrated a credible and practical path, through novel hardware and software, to realize the program objectives of ENLITENED. The net result will ensure that the United States maintains its strength in the crucial sector of Information Technology, which is vital to both our economic security and our national security.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Fission Meter Information Barrier Attribute Measurement System - NA-243 FNI/UKC FY2017 Task 1-2 Report

An SNM attribute Information Barrier (IB) system was developed for a 2011 US/UK Exercise. The system was modified and extensively tested in a 2013-2014 US-UK Measurement Campaign. This work demonstrated rapid deployment of an IB system for potential treaty use. The system utilizes an Ortec Fission Meter neutron multiplicity counter and custom computer code. The system demonstrates a proof-of-principle automated Pu-240 mass determination with an information barrier. After a software start command is issued, the system automatically acquires and downloads data, performs an analysis, and displays the results. This system conveys the results of a Pu mass threshold measurements in a way the does not reveal sensitive information. In full IB mode, only the pass/fail result is displayed as a “Mass <= Threshold Amount” or “Mass >= Threshold Amount” as shown in Figure 4. This can easily be adapted to a red/green “lights” display similar to the Detective IB system for Pu isotopics as shown in Figure 6. In test mode, more detailed information is displayed. The code can also read in, analyze, and display results from previously acquired or simulated data. Because the equipment is commercial-off-the-shelf (COTS), the system demonstrates a low-cost short-lead-time technology for treaty SNM attribute measurements. A deployed system will likely require integration of additional authentication and tamper-indicating technologies. This will be discussed for the project in this and future progress reports.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Network Traffic Generator for Low-rate Small Network Equipment Software

Application that uses the Python low-level socket interface to pass network traffic between devices on the local side of a NAT router and the WAN side of the NAT router. This application is designed to generate traffic that complies with the Energy Star Small Network Equipment Test Method.

Lanzisera, Steven↗

Real-Time Testbed for Transmission Line Protection

Hardware in the loop (HIL) testing is crucial for designing and managing electric power grids. These grids are becoming larger and more complex. The importance for students to have safe and intuitive ways to interact with the devices associated with the power grids has never been more crucial. Since most of these tests involve high voltages, this can be a deterrent for instructors and students in undergraduate programs. HIL testing is a solution to these common issues. This method has become one of the most popular methods for testing these power systems. With the use of Western Michigan University’s (WMU) Real-Time Digital Simulator (RTDS) and SEL-421-7 protection relay, a HIL testbed has been created. These devices were interconnected using the communication protocol known as Generic Object-Oriented Substation Event (GOOSE). A simulated transmission line system was modeled in an RTDS software RSCAD as the basis for this testbed. This model simulated different types of faults that could occur in a transmission line while in operation. The SEL-421-7 relay is connected to the RSCAD simulation via GOOSE to protect our simulated transmission line. This testbed was set up to give students a clear understanding of how distance protection works as well as how the SEL-421-7 will react to various kinds of faults, in addition to how useful the RTDS can be when testing different power systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Validation of Tendril TrueHome Using Software-to-Software Comparison

This study performed comparative evaluation of EnergyPlus version 8.6 and Tendril TrueHome, two physics-based home energy simulation models, to identify differences in energy consumption predictions between the two programs and resolve discrepancies between them. EnergyPlus is considered a benchmark, best-in-class software tool for building energy simulation. This exercise sought to improve both software tools through additional evaluation/scrutiny.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Using Low-Cost “Garage Band” Recording Technology for Acquiring High Resolution High-Speed Data

The Oak Ridge National Laboratory (ORNL) has developed and tested a novel system architecture for acquiring high fidelity high-speed data. The approach uses a consumer grade audio recording device that is normally associated with “garage band” recording of music. ORNL has coupled this low-cost data acquisition hardware with computing technology running open-source software. The main advantage of this approach is per-channel cost; an instrument grade data acquisition system typically costs between $800 to $2000 per channel compared to less than $50 per channel for these consumer grade components. Three systems, each featuring four channels, have been deployed for acquiring data from geophones and the electrical supply system that supports the High Flux Isotope Reactor (HFIR) and the Radiochemical Engineering Development Center (REDC) at ORNL. Each channel samples at 96 kHz at 24-bit resolution. The deployed systems operate continuously 24/7 and produce about 4 terabytes of data per month per system. This paper provides a technical overview of this approach, its implementation, and some preliminary results from qualification testing. This work was conducted in support of the Multi-Informatics for Nuclear Operations Scenarios (MINOS).Keywords: Data acquisition Measurement Informatics

Wetherington Jr, G↗

SU-E-T-192: Commissioning of a Commercial 3D Dose Calculation Program

Purpose: To commission a commercial software package (CSP) that is used as secondary dose calculation check. The CSP uses an independent golden data beam model. However, some parameters can be modified to generate a customer specific model. Plan comparisons and point dose measurements were performed to test if and to what extent the beam model needed adjustment to optimize results. Methods: Beam parameter configurations were compared between the CSP and both TPS. Twelve phantom test plans ranging from simple to complex were generated in two treatment planning systems (TPS). Tests included small field, off axis, EDW, IMRT and VMAT plans. For each plan a point dose was measured to establish ground truth. Lastly, patient plans were compared for both TPS systems and the CSP. Results: Beam parameters agreed within 2%. The output factors for small fields were changed for the 15 MV beam by 2 and 1.5 % for the 1 cm and 2 cm field sizes, respectively. For the 6 MV beam output factors were adjusted by 3−0.8% for field sizes ranging from 1 to 5 cm. The MLC dynamic leaf gap was adjusted by 1.5 mm for 18 MV beam. Differences between the CSP and the TPS were noted in the built-up region. These differences affected the gamma pass rate in the surface region, however this effect is reduced with increasing number of beam angles and does not affect point dose calculations at depth. All IMRT and VMAT plans agreed with the CSP using a gamma pass rate of 95% (3%, 3mm). Conclusion: The CSP is used to verify point doses for all 3D plans generated in our clinic for the last 6 months. No point dose mismatches were encountered since the CSP was implemented. Next, the CSP will be adapted for secondary checks of all IMRT plans. KL had a beta tester agreement with Mobius Medical for an in-kind equipment and software loan.

60 APPLIED LIFE SCIENCES↗

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