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At least 199 records · Page 11

Concentrating Solar Power Best Practices Study

The primary objective of this Concentrating Solar Power Best Practices Study is to publish best practices and lessons learned from the engineering, construction, commissioning, operations, and maintenance of existing concentrating solar power (CSP) parabolic trough and power tower systems. To accomplish this objective, information was solicited from many owners, operators, and engineering, procurement, and construction (EPC) contractors, independent engineers, and other stakeholders of parabolic trough and central receiver plants (also commonly referred to as power towers). Information was gathered through in-person or online meetings, site visits, and questionnaires sent to participants. The project team held about 50 information-gathering sessions with participants over the course this effort; and in the process, it collected information from participants representing nearly 80% of CSP plants operating worldwide.

14 SOLAR ENERGY↗

A Simple Program to Estimate the Fast Modular Reactor Steady-State Closed Brayton Cycle Operating Parameters

The Fast Modular Reactor (FMR) is a gas-cooled fast reactor (GFR) that produces a net electricity output of 50 MW with helium-driven closed Brayton cycle. The power plant includes reactor system and power conversion unit (PCU). The reactor system produces fission energy that is transferred by helium flow. The PCU consists of a turbine, two compressors, and three heat exchanges. More specifically, the recuperator is a counter-flow energy recovery heat exchanger. The precooler and intercooler are the heat sinks. To analyze and understand the sensitivity of plant performance to the design parameters, a numerical program was written to calculate the plant operating parameters represented by the helium temperature, pressure, mass flow, and the heat sink temperatures. The program was developed for the steady-state operating condition. etc.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Instrumentation and Control Needs for Reliable Operation of Lunar Base Surface Nuclear Power Systems

As one of the near-term goals of the President's Vision for Space Exploration, establishment of a multi-person lunar base will require high-endurance power systems which are independent of the sun, and can operate without replenishment for several years. These requirements may be obtained using nuclear power systems specifically designed for use on the lunar surface. While it is envisioned that such a system will generally be supervised by humans, some of the evolutions required maybe semi or fully autonomous. The entire base complement for near-term missions may be less than 10 individuals, most or all of which may not be qualified nuclear plant operators and may be off-base for extended periods thus, the need for power system autonomous operation. Startup, shutdown, and load following operations will require the application of advanced control and health management strategies with an emphasis on robust, supervisory, coordinated control of, for example, the nuclear heat source, energy conversion plant (e.g., Brayton Energy Conversion units), and power management system. Autonomous operation implies that, in addition to being capable of automatic response to disturbance input or load changes, the system is also capable of assessing the status of the integrated plant, determining the risk associated with the possible actions, and making a decision as to the action that optimizes system performance while minimizing risk to the mission. Adapting the control to deviations from design conditions and degradation due to component failures will be essential to ensure base inhabitant safety and mission success. Intelligent decisions will have to be made to choose the right set of sensors to provide the data needed to do condition monitoring and fault detection and isolation because of liftoff weight and space limitations, it will not be possible to have an extensive set of instruments as used for earth-based systems. Advanced instrumentation and control technologies will be needed to enable this critical functionality of autonomous operation. It will be imperative to consider instrumentation and control requirements in parallel to system configuration development so as to identify control-related, as well as integrated system-related, problem areas early to avoid potentially expensive work-arounds . This paper presents an overview of the enabling technologies necessary for the development of reliable, autonomous lunar base nuclear power systems with an emphasis on system architectures and off-the-shelf algorithms rather than hardware. Autonomy needs are presented in the context of a hypothetical lunar base nuclear power system. The scenarios and applications presented are hypothetical in nature, based on information from open-literature sources, and only intended to provoke thought and provide motivation for the use of autonomous, intelligent control and diagnostics.

Turso, James↗

Solar Power System Evaluated for the Human Exploration of Mars

The electric power system is a crucial element of any mission for the human exploration of the Martian surface. The bulk of the power generated will be delivered to crew life support systems, extravehicular activity suits, robotic vehicles, and predeployed in situ resource utilization (ISRU) equipment. In one mission scenario, before the crew departs for Mars, the ISRU plant operates for 435 days producing liquefied methane and oxygen for ascent-stage propellants and water for crew life support. About 200 days after ISRU production is completed, the crew arrives for a 500-day surface stay. In this scenario, the power system must operate for a total of 1130 days (equivalent to 1100 Martian "sols"), providing 400 MW-hr of energy to the ISRU plant and up to 18 kW of daytime user power. A photovoltaic power-generation system with regenerative fuel cell (RFC) energy storage has been under study at the NASA Glenn Research Center at Lewis Field. The conceptual power system is dominated by the 4000- m2 class photovoltaic array that is deployed orthogonally as four tent structures, each approximately 5 m on a side and 100-m long. The structures are composed of composite members deployed by an articulating mast, an inflatable boom, or rover vehicles, and are subsequently anchored to the ground. Array panels consist of thin polymer membranes with thin-film solar cells. The array is divided into eight independent electrical sections with solar cell strings operating at 600 V. Energy storage is provided by regenerative fuel cells based on hydrogen-oxygen proton exchange membrane technology. Hydrogen and oxygen reactants are stored in gaseous form at 3000 psi, and the water produced is stored at 14.7 psi. The fuel cell operating temperature is maintained by a 40-m2 deployable pumped-fluid loop radiator that uses water as the working fluid. The power management and distribution (PMAD) architecture features eight independent, regulated 600-Vdc channels. Power management and distribution power cables use various gauges of copper conductors with ethylene tetrafluoroethylene insulation. To assess power system design options and sizing, we developed a dedicated Fortran code to predict detailed power system performance and estimate system mass. This code also modeled the requisite Mars surface environments: solar insolation, Sun angles, dust storms, dust deposition, and thermal and ultraviolet radiation. Using this code, trade studies were performed to assess performance and mass sensitivities to power system design parameters (photovoltaic array geometry and orientation) and mission parameters (landing date and landing site latitude, terrain slope, and dust storm activity). Mission analysis cases were also run. Power results are shown in this graph for an analysis case with a September 1, 2012, landing date; 18.95 North latitude landing site; two seasonal dusts storms; and tent arrays. To meet user load requirements and the ISRU energy requirement, an 8-metric ton (MT) power system and 4000-m2 photovoltaic array area were required for the assumed advanced CuInS2 thin-film solar cell technology. In this figure, the top curve is the average daytime photovoltaic array power, the middle curve is average daytime user load power, and the bottom curve is nighttime power. At mission day 1, daytime user power exceeds 120 kW before falling off to 80 kW at the end of the mission. Throughout the mission, nighttime user power is set to the nighttime power requirement. In this analysis, "nighttime" is defined as the 13- to 15-hr period when array power output is below the daytime power requirement. During dust storms, power system capability falls off dramatically so that by mission day 900, a daily energy balance cannot be maintained. Under these conditions, the ISRU plant is placed in standby mode, and the regenerative fuel cell energy storage is gradually discharged to meet user loads.

Kerslake, Thomas W.↗

Development of Reduced Glass Furnace Model to Optimize Process Operation

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and PPG Industries to develop a reduced-order glass furnace model that enables plant operators to make informed, realtime process adjustments. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (HPC4Mfg) Program of the Department of Energy's Advanced Manufacturing Office (AMO) within the Energy Efficiency and Renewable Energy (EERE) Office. This program ran from June 2016 to July 2017 with no extensions.

42 ENGINEERING↗

Concrete Thermal Energy Storage Enabling Flexible Operation without Coal Plant Cycling

The work described in this report is responsive to the Office of Fossil Energy program “Energy Storage for Fossil Power Generation.” The pilot plant built as a result of this project demonstrated the feasibility and performance of a concrete thermal energy storage (CTES) system integrated with a supercritical coal power plant. The 10 MWh electrical (>25 MWh thermal) CTES unit, developed by Storworks Power, was designed to enable flexible operation of coal plants without cycling damage. The project's key technical achievements showcase a significant advancement in energy storage technology. A modular CTES system using 42 “Bolderblocs” units was successfully designed and constructed at Alabama Power’s Plant Gaston Unit 5, with each block containing embedded stainless-steel coils in specialized, cost-effective high-temperature concrete. The system interfaced seamlessly with the plant's 3500 psig (241 barg), 1000°F (538°C) supercritical steam, demonstrating operational flexibility. Over 86 full cycles, the CTES exhibited rapid charging and discharging capabilities, effectively mimicking steam turbine feed conditions and handling varying load profiles and storage durations. Performance validation confirmed the system's ability to consistently meet design target steam conditions of 75 bar-a and ~400°C for nominal baseline discharge. The concrete material withstood repeated thermal cycling without degradation, validating earlier lab-scale tests. Integration of balance of plant components, including a condensate management system with storage tank and air-cooled condenser, minimized plant interfaces and water consumption. A robust control scheme ensured safe, automated operation across various scenarios. Key learnings from the project were invaluable: 1. Initial concrete drying and commissioning procedures were refined for future deployments, enhancing efficiency in subsequent installations. 2. System flexibility exceeded expectations, with rapid response to changing conditions. 3. Design improvements were identified including optimized insulation and piping that will enhance overall system efficiency in future deployments 4. Full cycle thermal roundtrip efficiencies exceeded 88%. While the roundtrip electrical efficiency was somewhat limited by known challenges using input steam, such constraints may be mitigated by swapping steam for hot air as thermal input. 5. A summary of key performance parameters for the pilot test and predicted performance of a full scale commercial system with specified improvements determined from the pilot are shown in Section 8. The project faced challenges, including COVID-19 delays and host plant availability constraints. However, these were overcome through adaptive planning and execution. The successful management of these obstacles demonstrated the resilience and adaptability of the project team and the robustness of the CTES technology. This successful pilot demonstrates the potential for CTES to enhance coal plant flexibility, supporting grid stability as renewable penetration increases. The validated design and operational data provide a solid foundation for scaling up to utility-scale implementations, potentially transforming how thermal plants operate in evolving energy landscapes. The system's ability to rapidly respond to changing grid conditions while maintaining high efficiency makes it a promising solution for balancing intermittent renewable energy sources. Furthermore, the project highlighted the potential for even greater efficiencies in future iterations. The use of air as an input medium could potentially eliminate the limitations observed with steam input, opening new possibilities for energy storage applications beyond coal plant integration. In conclusion, this pilot project not only achieved its primary goals but also uncovered additional benefits and potential applications of the CTES technology. It represents a significant step forward in addressing the challenges of grid stability and flexibility in an increasingly renewable-driven energy landscape.

01 COAL, LIGNITE, AND PEAT↗

Application of Cable Condition Monitoring Technologies to Assess Age-Related Degradation of Industrial Cables Installed in Harsh Environments

The aging of electrical cables has been the subject of substantial research and development (R&D) projects performed by national and international laboratories, universities, and private organizations for many years. This R&D was conducted to develop guidance, equipment, and techniques to support aging management of in-service cables in industrial facilities such as nuclear power plants, research reactors, waste facilities, and fuel fabrication plants. Through these research efforts, condition monitoring technologies have been developed that can determine the severity of age-related degradation that occurs in industrial cables and insulation polymers during service. This paper summarizes the results of aging assessments that were performed for cables installed in two U.S. nuclear power plants, one a pressurized water reactor and one a boiling water reactor. These cables had been in service for over 40 years and during plant operation were exposed to harsh environmental conditions including elevated temperatures and radiation. For these assessments, a comprehensive series of measurements was performed to assess the aged condition of the cables. These cables came from different manufacturers, were manufactured in different years, and were constructed with a variety of jacket and insulation polymers including chloro-sulfonated polyethylene (CSPE), cross-linked polyethylene (XLPE)/cross-linked polyolefin (XLPO), neoprene, and ethylene propylene rubber (EPR). The goal of these assessments was to determine the current aged condition of the cable polymers and provide an estimate of how long the cable insulation materials could remain exposed to their in-service environmental conditions before reaching their end-of-life condition. Both nuclear power plants have received license renewals to extend their operation from 40 to 60 years, and the utilities need objective evidence to show that critical components such as cables will be able to function safely and reliably during the extended operating period. Furthermore, the results of these assessments showed that the cables exhibited different aged conditions depending on the type of polymers they were constructed with and the environment they were exposed to during service. Some of the cables and insulation polymers showed signs of significant age-related degradation and were estimated to have approximately 5 years of remaining service life. Other cables exhibited no signs of significant age-related degradation and were estimated to have 50 years or more of remaining service life. Using the results of these cable aging assessments, plant personnel were able to (1) determine the overall aged condition of cables and insulation polymers using objective test results, (2) identify aged or degraded cables before they caused operability issues, and (3) avoid unnecessary and costly replacement of cables that can continue to operate safely and reliably.

36 MATERIALS SCIENCE↗

Modeling and Analysis of Wind Turbine Wake Vortex Evolution Due to Time-Constant Spatial Variations in Atmospheric Flow

Modern utility-scale wind turbines are evolving toward larger, lighter, and more flexible designs to meet the growing demand for renewable energy while minimizing logistical costs. However, these advancements in lightweight design result in heightened aeroelastic sensitivity, leading to complex interactions which affect the rotor’s capacity to withstand aerodynamic loading and the cascading effects that manifest in the wake’s vortex-structure evolution under variable atmospheric conditions. In this paper, we analyze the influence of stream-wise fluctuating atmospheric flow conditions on wind turbines with large, flexible rotors through simulations of the National Rotor Testbed (NRT) turbine, located at Sandia National Labs’ Scaled Wind Farm Technology (SWiFT) facility in Lubbock, Texas. The Common Ordinary Differential Equation Framework (CODEF) modeling suite is used to simulate wind turbine aeroelastic oscillatory behavior and wind farm vortex–wake interactions for a range of conditions with spatially variant atmospheric flow. CODEF solutions for turbine operation in wind conditions featuring only one parameter fluctuation are compared to wind conditions with several wind parameter variations in combination. By isolating individual inflow variations and comparing them to multi-parameter scenarios, we determine the contributions of each atmospheric factor to rotor dynamics, wake evolution, and downstream wind farm interactions. The purpose of this paper is to analyze the effects of spatial variations in atmospheric flow on the topological evolution of wind turbine vortex wakes, which constitutes a gap in the current understanding of wind turbine wake dynamics. The insights gained from this study are particularly valuable for the development of wind farm control strategies aimed at mitigating the adverse effects of wake interactions, enhancing energy capture, and improving the overall stability of wind farm operations. With these insights, we aim to contribute to the development of modeling and simulation tools to optimize utility-scale wind power plants operating in diverse atmospheric environments.

Farrell, Alayna (ORCID:000000023555720X)↗

Modeling the Risk of U.S. Offshore Oil & Gas Exploration-Well Drilling, Commercial Nuclear Plants, and Human Spaceflight

Probabilistic Risk Assessment (PRA) has been applied in different industries for many years. Each industry and technology area presents varying challenges and priorities, and the risk models therefore need to be somewhat different. This paper compares aspects of risk modeling of offshore drilling, nuclear plant operation, and human spaceflight. Risk models in all three technology areas have certain high-level similarities: (1) they employ redundancy and diversity in their means to prevent or mitigate risk, including a mix of active and passive systems designed to respond to off-normal evolutions; (2) they are affected by human reliability; (3) their models require consideration of coupling between scenario structure and scenario phenomenology. But in examining the models in more detail, one sees important differences in methodology and emphasis. For purposes of comparison, this paper discusses aspects of a risk model of an offshore drilling operation in the U.S. Gulf of Mexico, focusing on where such a development differs in important ways from models of commercial U.S. nuclear plants and models developed for human spaceflight.

Boyer, Roger L.↗

Uncrewed Lunar Surface Operations and Support Activities

Sustained human presence on the surface of the Moon and future missions to Mars require increased independence from surface crews and Earth-based mission control to operate efficiently, safely, and reliably. The time for surface crews to perform tasks will be limited. Extravehicular activities by surface personnel are burdensome and time-consuming, even when a continuous human presence on the surface occurs. Identifying and balancing human/automation roles and tasks and infusing automation and autonomy practices early in a system’s lifecycle will be essential to achieve mission objectives. Among these objectives are attaining a sustained human presence, improving performance and mission effectiveness, reducing operations and maintenance (O&M) costs, and ensuring operations that are robust to communication delays. To achieve these objectives, an operational shift toward increased automation and autonomy with less reliance on humans is needed. Uncrewed lunar surface operations and support activities occur when surface crews are not present or are independent of surface crew timeline activities requiring no surface crew oversight or intervention. These uncrewed surface opportunities can also be planned to minimize crew workload that avoids routine maintenance and support tasks, thus maximizing crew exploration time. Uncrewed preparations such as staging and prepositioning equipment and materials before the crew arrives could improve crew task efficiency. Additional opportunities exist to conduct uncrewed science, exploration, and utilization. Uncrewed surface architecture functions can include science and exploration; habitation; launch and landing support; surface communication and navigation; surface power generation and distribution; human surface mobility; lifting, handling, manipulating; excavation, construction, and site preparation; logistics management; maintenance and repair; surface resource utilization; integrated site operations and shared support services (e.g., site scheduling/prioritization, dust mitigation/contamination control, and surface safety). Early robotic lunar surface campaigns will provide information on the availability of resources, such as oxygen and water, and demonstrate surface-based technologies. After the Artemis III human lunar return mission, a series of landers will deliver surface systems, cargo, supplies, science packages, spare parts, and commodities. A balance of crewed and uncrewed surface operations will enable a sustained lunar surface presence at the South Pole of the Moon at a site that will be known as the Artemis Base Camp (ABC). It is envisioned that base camp operations on and around the Moon will then help prepare for the mission durations and activities needed to support the first human mission to Mars. Before long-duration crew missions to the base camp can occur, the necessary surface infrastructure will be pre-deployed and verified operational. Surface assets will be teleoperated and remotely managed from Earth. Additionally, robotic and short-duration crewed missions to the ABC will ensure the site’s merit to achieve long-term science objectives, availability of usable resources, and that terrain, seasonal variations, and illumination conditions are acceptable. ABC will consist of different areas where specific functions and services are rendered, including: • Launch and Landing Area • Habitation Area • Power Production Area • Resource Areas Launch and Landing Area—The launch and landing area will support associated functions for the arrival and departure of vehicles, such as crewed landing and ascent and uncrewed cargo deliveries and offloading. It will evolve from an unimproved site at the beginning of the exploration campaign to a more sustainable landing and launch area that can support repeated arrivals and departures. Initial uncrewed Lunar Terrain Vehicle (LTV) surface operations may include emplacement of navigation beacons and communication equipment, real-time video and photography of landing/liftoff events, and element repositioning, such as portable utility power (PUP) (applicable for other landed assets at other areas). Site preparations, such as surface leveling, soil compaction, and berm/path construction, may be needed for a more sustainable launch and landing area capable of accommodating vehicles that are increasingly more reusable and reduce the effects of plume surface interactions and ejecta impacts on nearby surface assets. During the ABC missions, cargo and logistics will be delivered to the lunar surface via robotic cargo landers before the crew arrives. These shipments, which can arrive in pressurized logistics carriers, will deliver the logistics necessary to support a crewed mission and include items such as food, water, equipment spares, etc. Providing the capability to retrieve, offload, and transport the logistics closer to the ABC site before the arrival of the crew will increase the overall efficiency of crew operations once they arrive. In the sustained phase of exploration, other supporting services may be needed, such as lander propellant servicing, surface power services, commodity refreshes, and additional inspection, maintenance, and repair capabilities, to sustain a cadence of extended personnel stays and cargo arrivals and departures. Habitation Area—Uncrewed support to surface habitation could involve supporting activation and pre-entry operations of the habitat while the crew is in orbit at the Gateway outpost preparing for a surface landing. Surface Habitat (SH) uncrewed operations may include bringing the cabin environment to a habitable temperature and air mix and activating other critical crew support systems. Potential crop production uncrewed tasks in the SH could also include autonomous watering and tending. Additionally, when the crew departs, the SH enters dormancy for the long period of uncrewed operation. A logistical staging area could also be collocated near the SH. If so, staging operations for crew supplies, waste re-location, and recycling operations may be opportunities for uncrewed operations. Power Production Area—The Fission Surface Power (FSP) element and its supporting distribution equipment provide power to surface elements as needed across the ABC to supplement day-to-day operations and survive lunar nights. Uncrewed support of this power system includes any initial LTV-assisted deployments of cables and other distributed equipment, associated electrical connections, and system testing and activation operations. Robotically performing some inspections, maintenance, or repair tasks on the power distribution equipment could reduce the surface crew workload. Resource Area— Uncrewed resource prospecting, mapping, and characterizing possible resource sites is likely to be time-consuming and represents an opportunity for uncrewed operations between crewed missions. Uncrewed mobile equipment operations will be needed in the extreme environments of permanently shadowed locations where resource extractions occur. As In-Situ Resource Utilization (ISRU) pilot plant operations begin, uncrewed surface support activities with available mobile and portable assets (LTV, PUP, etc.) will better support these operations. Any produced commodities can be stored at a centralized storage location for future use. Also associated with these operations is the use of mobile robotic excavators for resource acquisition and robotic/autonomous regolith processing. The waste tailings generated during excavation and regolith processing would also need to be transported and deposited at a dedicated location. Surface assets will continue operating between crew visits to maintain surface capabilities, conduct lunar surface science, technology demonstrations, and public outreach opportunities. Additionally, certain sustaining tasks that would consume valuable crew time could be performed before crew arrival, or after their departure. This capability may offer more affordable options to construct, activate, test, and maintain a broad set of surface assets. Telerobotically operated human surface mobility systems, such as the LTV and Pressurized Rover (PR), can be utilized for various tasks. Surface environmental conditions pose a distinct challenge for all these activities. Surface illumination and localized shadows are one such factor. Night-survival operations could consist of thermal management, battery pre-charging, and load shedding. Some surface systems may hibernate through the night and then awake and continue nominal operations. Uncrewed mobile assets may use a more adaptive approach to optimize their power and operations; one method is to follow the sunlight. Night-survival operations may be initiated remotely by teleoperation, automated, or accomplished by supervised autonomous operation. The ability to pre-deploy and control remote assets in orbit or on Mars before the arrival of the mission crew is a key capability that can be simulated on the moon. The base camp provides a venue where these advanced operational concepts, technologies, and autonomous methods and techniques, including the incorporation of time delays to simulate Earth-Mars latency can be replicated to help buy down future Mars mission risks. This paper will examine the evolution of uncrewed lunar surface operations and support activities. It will also discuss the lunar surface environmental conditions (thermal, lighting, terrain, topography, communications) along with the challenges they pose on uncrewed surface operations, and the performance of these activities with limited to minimal human interaction and/or teleoperation. Since lunar missions include Mars mission analogs, such investigation provides the framework for future uncrewed Mars mission support.

Mark E Lewis↗

Towards a Deeper Understanding of Automation Transparency in the Operation of Nuclear Plants

Automation technologies have the potential to reduce operations and maintenance costs, ensure reliable power generation and safety, and thereby contribute to extending the lifespan of nuclear power plants. To fulfill this aspiration, automation behaviors have to be understandable and predictable to human operators and traceable for license holders and regulators in the event of automation failures. The current report investigates how automation transparency as a systems design principle can keep operators sufficiently informed about the inner workings of automation or make fail-safe automation run invisibly in the background to free up operator capacity.

99 GENERAL AND MISCELLANEOUS↗

Development of an In-Situ Method for Cable Condition Monitoring in Nuclear Power Plants (SBIR Phase IIB Final Report)

This is the final report of a Small Business Innovation Research (SBIR) project that Analysis and Measurement Services Corporation (AMS) has conducted for the U.S. Department of Energy (DOE) over a seven-and-a-half year period (February 2013 through April 2020 with the awards of Phase I, Phase II and Phase IIB projects). The goal of the project was to design, develop, validate, and demonstrate a technique for in-situ testing of cable insulation polymers that will identify, locate, and provide the degree of aging for cables commonly used in nuclear power plants. During the Phase I project, AMS established that the frequency domain reflectometry (FDR) technique can successfully identify and measure cable insulation degradation that can be trended with aging. In Phase II, AMS performed extensive cable aging studies to correlate FDR measurements with other laboratory condition monitoring techniques and developed aging condition categories to quantify the severity of insulation degradation. In Phase IIB, the project expanded the research to include a wider variety of cable polymers that are used in the commercial nuclear power industry. This work also involved developing acceptance criteria to objectively assess age-related cable degradation while sharing the results of this research with industry, academia, and national laboratories to advance the state of the art in cable aging management technologies. The products developed under this research project provide the nuclear industry with an effective condition monitoring tool to support safe and long-term plant operation. Throughout the project, collaborations and support were received from a variety of industry organizations and individuals including DOE National Laboratories as well as nuclear plant utilities and several other industry experts and cable manufacturers. Contributions from these organizations included the donation of new cables, naturally aged cables, and research collaboration. The validation and commercialization of the products of this project were achieved through opportunities to test and demonstrate the technologies’ capabilities on-site at nuclear power generation and research facilities as well as in the laboratory alongside industry peers and cable testing service companies. The research resulted in a technology that can be used to identify, locate, and quantify age-related degradation in several types of cable polymers. This included developing software and hardware as well as the methodology for using the FDR technique to assess age-related degradation of installed cables. The technology developed under this project can provide nuclear plant management, engineers, and technicians with an in-situ electrical test method to determine if in-service cables need to be replaced, monitored on a periodic basis, or show no evidence of significant age-related degradation that may require action. Near the end of this Phase IIB project, the FDR product was sold to a nuclear power utility in South Korea. This sale of a dedicated aging assessment tool is the beginning of a comprehensive contract with the expectation of twelve (12) units sold to that country. Additionally, the FDR technology has been sold to several industry organizations including a nuclear research institute and the Diablo Canyon nuclear power plant. This technology is also being leased by other nuclear industry service companies for incorporation into aging management programs. The cable testing technology that was developed under this project was also integrated into a comprehensive cable aging assessment service that is being offered to the nuclear industry at the request of U.S. nuclear utilities and is currently part of onsite testing services provided by AMS.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Confinement performance predictions for a high field axisymmetric tandem mirror

This paper presents a Hammir tandem mirror confinement performance analysis based on Realta Fusion’s first-of-a-kind model for axisymmetric magnetic mirror fusion performance. This model uses an integrated end plug simulation model including, heating, equilibrium and transport combined with a new formulation of the plasma operation contours (POPCONs) technique for the tandem mirror central cell. Using this model in concert with machine learning optimization techniques, it is shown that an end plug utilizing high temperature superconducting magnets and modern neutral beams enables a classical tandem mirror pilot plant producing a fusion gain Q > 5. The approach here represents an important advance in tandem mirror design. The high-fidelity end plug model enables calculations of heating and transport in the highly non-Maxwellian end plug to be made more accurately. The detailed end plug modelling performed in this work has highlighted the importance of classical radial transport and neutral beam absorption efficiency on end plug viability. The central cell POPCON technique allows consideration of a wide range of parameters in the relatively simple near-Maxwellian central cell, facilitating the selection of more optimal central cell plasmas. These advances make it possible to find more conservative classical tandem mirror fusion pilot plant operating points with lower temperatures, neutral beam energies and end plug performance requirements than designs in the literature. Despite being more conservative, it is shown that these operating points have sufficient confinement performance to serve as the basis of a viable fusion pilot plant provided that they can be stabilized against magnetohydrodynamic and trapped particle modes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Confinement performance predictions for a high field axisymmetric tandem mirror

This paper presents Hammir tandem mirror confinement performance analysis based on Realta Fusion's first-of-a-kind model for axisymmetric magnetic mirror fusion performance. This model uses an integrated end plug simulation model including, heating, equilibrium, and transport combined with a new formulation of the plasma operation contours (POPCONs) technique for the tandem mirror central cell. Using this model in concert with machine learning optimization techniques, it is shown that an end plug utilizing high temperature superconducting magnets and modern neutral beams enables a classical tandem mirror pilot plant producing a fusion gain Q > 5. The approach here represents an important advance in tandem mirror design. The high fidelity end plug model enables calculations of heating and transport in the highly non-Maxwellian end plug to be made more accurately. The detailed end plug modelling performed in this work has highlighted the importance of classical radial transport and neutral beam absorption efficiency on end plug viability. The central cell POPCON technique allows consideration of a wide range of parameters in the relatively simple near-Maxwellian central cell, facilitating the selection of more optimal central cell plasmas. These advances make it possible to find more conservative classical tandem mirror fusion pilot plant operating points with lower temperatures, neutral beam energies, and end plug performance requirements than designs in the literature. Despite being more conservative, it is shown that these operating points have sufficient confinement performance to serve as the basis of a viable fusion pilot plant provided that they can be stabilized against MHD and trapped particle modes.

FOS: Physical sciences↗

Assessment of the Effect of Prototypic High-Burnup Operating Conditions of Fuel Fragmentation, Relocation, and Dispersal Susceptibility

The US nuclear energy industry is investigating strategies that further reduce the cost of energy production by using its existing fleet of nuclear generating stations. Most nuclear power plant operating costs are associated with purchasing fresh fuel assemblies or the efficiency of the reactor core design. Material costs are typically beyond the operator’s control; however, the core design optimizations offer potential operational savings. The core design envelope available to operators is constrained by two primary regulatory criteria: an enrichment limit of 5% 235 U and a burnup limit of 62 GWD/tU. These constraints have resulted in renewed efforts by the nuclear industry to pursue extending the peak rod-average burnup beyond 62 GWd/tU. This effort will likely require additional safety analyses beyond what is currently accepted by the US Nuclear Regulatory Commission. The purpose of this work is to demonstrate a best estimate plus uncertainty pin-by-pin high-burnup loss of coolant accident analysis technique to assess full-core high-burnup fuel fragmentation, relocation, and dispersal (FFRD) and identify approaches for minimizing or potentially mitigating FFRD through core design optimizations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A digital twin approach to system-level fault detection and diagnosis for improved equipment health monitoring

Automating the task of fault detection and diagnosis is crucial in the effort to reduce the operation and maintenance cost in the nuclear industry. This paper describes a physics-based approach for system-level diagnosis in thermal-hydraulic systems in nuclear power plants. The inclusion of physics information allows for the creation of virtual sensors, which provide improved fault diagnosis capability. The physics information also serves to better constrain diagnostic solutions to the physical domain. As a demonstration, various test cases for fault diagnosis in a high-pressure feedwater system were considered. The use of virtual sensors allows constructing performance models for two first-point feedwater heaters which would not have been possible otherwise due to the limited sensor set. Real-time plant data provided by a utility partner were used to assess the diagnostic approach. The detection of an abnormal event immediate after a plant startup pointed to faulty behaviors in the two first-point feedwater heaters. Further, this double-blind fault diagnosis was subsequently confirmed by the plant operator. In addition, several simulated sensor fault events demonstrated the capability of our algorithms in detecting and discriminating sensor faults.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Wind Turbine Drivetrain Reliability Research - Gearbox Bearing Axial Cracking Failure Mode Example

The U.S. Department of Energy's National Renewable Energy Laboratory and Argonne National Laboratory have been conducting wind turbine drivetrain (formerly gearbox) reliability research for many years. Although the drivetrain focus has not changed, detailed projects are adjusted every few years based on dynamic needs seen in the field across the wind industry. This webinar will walk through the research methodology by using wind turbine gearbox bearing axial cracking failure mode as an example. The detailed steps include: 1) top failure mode identification based on actual failure data collected from project partners, 2) bench-top testing to identify possible contributing factors and formulate a damage metric, 3) physics domain modeling and validation through testing, 4) reliability assessment and prognosis based on the physics domain model and data domain inputs, and further enhancement through machine learning algorithms, using actual wind plant operational and failure event data. Hopefully, the presented work is of interest to the IISE community, and some members can apply their expertise to wind turbine and plant applications, helping enhance wind power generation technology advancement and its broader deployment.

axial cracking↗

Roadmap for Deployment of Modularized Hydrothermal Liquefaction: Understanding the Impacts of Industry Learning, Optimal Plant Scale, and Delivery Costs on Biofuel Pricing

Hydrothermal liquefaction (HTL) is a promising technology for converting abundant organic wastes into fuels. Previous techno-economic analyses (TEAs) of HTL have been used to estimate the minimum fuel selling price (MFSP) of biofuel products, but these analyses often assume a bespoke plant design where each plant operates under unique process conditions and neglect transportation costs. However, transportation costs must be included in realistic TEAs, and further, a mass-produced fixed-scale modular plant design approach may be more effective than case-by-case plant design, provided that there is sufficient market capacity to benefit from modularization. This study estimates fuel price behavior in the presence of transportation costs and benefits stemming from modular plant design. This analysis indicates that a modular process capable of handling 60 dry tons per day (DTPD) is optimal, resulting in a ~25% reduction in MFSP (from $4.70/GGE, fully upgraded) at complete market feedstock utilization compared with case-by-case design. The associated cost reductions are attributable to learning benefits and modularization. Several HTL deployment “roadmaps” are then explored, with each roadmap consisting of different periods of case-by-case design followed by adoption of a modularized approach. A period of nonmodular industry growth up to market saturation of ~7% followed by implementation of modular plant design strikes a balance between the investment risk and learned cost reductions associated with modular plant design. However, if bespoke plants built during this period of nonmodular growth saturate more than 23% of available feedstock, learned cost reductions are significantly diminished. Here, this study points to the potential benefits of modularized and decentralized waste-to-energy processes when the modularization follows an optimal deployment strategy.

09 BIOMASS FUELS↗