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At least 271 records · Page 15

On the Road to Achieving Safety Excellence at the Idaho Cleanup Project: The Initial Challenges, Solutions, and Positive Results of Striving to be the Best and Safest in the DOE Complex - 20518

When Fluor Idaho, LLC (Fluor Idaho) assumed the Idaho Cleanup Project Core contract (ICP Core) in mid-2016, it inherited the successful multi-faceted, employee-owned safety programs of two prior contractors supporting cleanup operations at the Idaho National Laboratory Site. Fluor Idaho incorporated the best of both safety programs along with Fluor Corporate's 106-year legacy of safety initiatives and successes. Fluor Idaho integrated the separate programs and cultures under a One Fluor approach - one project, one mission, One Fluor. Job changes, management changes, and procedures, processes, and system changes presented multiple challenges. Those challenges combined with the severe Winter of 2016/2017 resulted in numerous slips, trips, and falls first aids and reportable injuries. The road to safety excellence started off bumpy and stayed that way for some time. Since then, Fluor Idaho has successfully implemented several key initiatives including employee engagement; management engagement and time in the field; communications improvements; safety culture sustainment; injury/illness prevention; organizational learning; and DOE Voluntary Protection Program (VPP) readiness and preparation. Management became more engaged by making more workplace visits and increasing their supervision of 'life critical work' or complex activities. Additional training became mandatory for first-line supervisors and front-line workers. Most recently, Fluor Idaho increased its injury and illness prevention initiatives extensively. In the last year, things have turned around in a dramatic way. This shift is directly attributable to the significant number of initiatives launched in late 2017 and 2018. These initiatives addressed safety performance in the five key areas of the DOE VPP and promoted sustainability of the company's safety culture. The five key areas are: management leadership, employee involvement, work-site analysis, hazard prevention and control, and safety and health training. Employees and managers alike recommitted to making safety the highest value. The result of this laser-like focus on safety and accident and injury prevention is that injuries and first aids are a fraction of what they were. During FY 2019, employees worked more than 4.2 million hours without a serious injury or lost work-day and 1 million hours without a recordable injury. Fluor Idaho is proud of its safety trend. The company invested significant resources in improving its safety record, and that investment is paying off. Other contractors in the DOE Complex can learn and benefit from this discussion of the challenges Fluor Idaho faced, as well as its innovative safety initiatives that are producing results that are being recognized by our U.S. Department of Energy (DOE) customer. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Artificial Intelligence Thermostat to Detect Faults

Residential air conditioners and heat pumps often experience faults due to inadequate maintenance, which can severely reduce efficiency or even cause system failure. Common issues include dirty or clogged air filters and refrigerant leaks. These problems degrade performance and increase energy use and operating costs. This study presents a smart thermostat with embedded artificial intelligence to detect such faults and alert homeowners when maintenance is needed. The thermostat uses low-cost measurements—including return-air temperature, relative humidity, supply-air temperature, outdoor-air temperature, and condenser subcooling—to identify abnormal operations. Because different faults produce distinct response patterns, tailored algorithms are developed to recognize characteristic fault signatures. The investigation is built on a detailed co-simulation platform that couples EnergyPlus with the DOE/ORNL Heat Pump Design Model (HPDM). EnergyPlus represents the building’s dynamic environment, while HPDM is a high-fidelity, hardware-based model that can simulate fault-free performance as well as a wide range of faults, including gradual degradation such as minor refrigerant leakage. This platform provides a virtual training and testing environment that helps distinguish fault-induced behavior from normal operation and supports development of robust diagnostic algorithms. Using this framework, a Dynamic Bayesian Network was developed to identify two common faults—gradual refrigerant charge loss and indoor airflow blockage—and the AI-embedded thermostat was verified through annual building simulations.

Shen, Bo [ORNL] (ORCID:0000000336600393)↗

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗

Map reduce using coordination namespace hardware acceleration

A system and method for supporting data MapReduce operations in a tuple space/coordinated namespace (CNS) extended memory storage architecture. The system-wide CNS provides an efficient means for storing and communicating data generated by local processes running at the nodes, and coordinated to provide MapReduce operations in a multi-nodal system. A hardware accelerated mechanism supports map reduce sorting/shuffle operations and reduce operations according to an aggregate function. Local processes running at a node generate a tuple corresponding to data generated by a process, each tuple having a tuple name and tuple data value corresponding to the generated data. Each tuple is processed and stored at the node or another node, dependent upon its tuple name. Tuple records associated with a tuple name are accumulated at one or more nodes according to a linked list structure at each that is accessible via a hash table index pointer at the node.

Jacob, Philip↗

Savannah River Site Composite Analysis (FY2019 Annual Review)

The Savannah River Site (SRS) is a Department of Energy (DOE) site encompassing approximately 310 square miles in South Carolina. It is bounded on the southwest by the Savannah River (SR) and is situated approximately 12 miles south of Aiken, South Carolina, and 15 miles southeast of Augusta, Georgia. Construction of and subsequent operations at the SRS began in 1951 under the direction of the Atomic Energy Commission. The primary mission of the SRS was to produce tritium and plutonium for the national nuclear weapons complex. Between 1953 and 1955, SRS brought five reactors and various support facilities into operation in support of its primary mission. Support facilities included two chemical separations plants, a heavy water extraction plant, a nuclear fuel and target fabrication facility, a tritium extraction facility and waste management facilities. With the declining need for a large nuclear weapons stockpile since the end of the Cold War, many SRS facilities no longer produce or process nuclear materials. All reactors were shut down by 1993. However, the SRS Tritium Extraction Facility continues to supply DOE with tritium. Additionally, operations at the K-Area Complex currently provide interim safe storage for much of DOE’s excess plutonium (Pu) and high enriched uranium, in a building which formerly housed K Reactor. As the SRS mission has changed, many surplus facilities are being dispositioned safely and economically. SRS has completed extensive decommissioning activities in D-Area, M-Area, P-Area, R-Area, and T-Area, with groundwater (GW) remediation ongoing. High-level waste tanks continue to be emptied and closed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Helium plasma operations on ASDEX Upgrade and JET in support of the non-nuclear phases of ITER

For its initial operational phase, ITER has until recently considered using non-nuclear hydrogen (H) or helium (He) plasmas to keep nuclear activation at low levels. To this end, the Tokamak Exploitation Task Force of the EUROfusion Consortium carried out dedicated experimental campaigns in He on the ASDEX Upgrade (AUG) and JET tokamaks in 2022, with particular emphasis put on the ELMy H-mode operation and plasma-wall interaction processes as well as comparison to H or deuterium (D) plasmas. Both in pure He and mixed He + H plasmas, H-mode operation could be reached but more effort was needed to obtain a stable plasma scenario than in H or D. Even if the power threshold for the LH transition was lower in He, entering the type-I ELMy regime appeared to require equally much or even more heating power than in H. Suppression of ELMs by resonant magnetic perturbations was studied on AUG but was only possible in plasmas with a He content below 19%; the reason for this unexpected behaviour remains still unclear and various theoretical approaches are being pursued to properly understand the physics behind ELM suppression. The erosion rates of tungsten (W) plasma-facing components were an order of magnitude larger than what has been reported in hydrogenic plasmas, which can be attributed to the prominent role of He 2+ ions in the plasma. For the first time, the formation of nanoscale structures (W fuzz) was unambiguously demonstrated in H-mode He plasmas on AUG. However, no direct evidence of fuzz creation on JET was obtained despite the main conditions for its occurrence being met. The reason could be a delicate balance between W erosion by ELMs, competition between the growth and annealing of the fuzz, and coverage of the surface with co-deposits.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Forecasting for ESCAPE: A Multi-Institution Hybrid Forecasting and Nowcasting Operation for Sea-Breeze Convection Supporting a Ground-Based and Airborne Field Campaign

The Experiment of Sea-Breeze Convection, Aerosols, Precipitation and Environment (ESCAPE) field project deployed two aircraft and ground-based assets in the vicinity of Houston, Texas, between 27 May and 2 July 2022, examining how meteorological conditions, dynamics, and aerosols control the initiation, early growth stage, and evolution of coastal convective clouds. To ensure that airborne- and ground-based assets were deployed appropriately, a forecasting and nowcasting team was formed. Daily forecasts guided real-time decision-making by assessing synoptic weather conditions, environmental aerosol, and a variety of atmospheric modeling data to assign a probability for meeting specific ESCAPE campaign objectives. During the research flights, a small team of forecasters provided “nowcasting” support by analyzing radar, satellite, and new model data in real time. The nowcasting team proved invaluable to the campaign operation, as sometimes changing environmental conditions affected, for example, the timing of convective initiation. In addition to the success of the forecasting and nowcasting teams, the ESCAPE campaign offered a unique “testbed” opportunity where in-person and virtual support both contributed to campaign objectives. The forecasting and nowcasting teams were each composed of new and experienced forecasters alike, where new forecasters were given invaluable experience that would otherwise be difficult to attain. Both teams received training on forecast models, map analysis, Hybrid Single-Particle Lagrangian Integrated Trajectory model (HYSPLIT), and thermodynamic sounding analysis before the beginning of the campaign. In this article, the ESCAPE forecasting and nowcasting teams reflect on these experiences, providing potentially useful advice for future field campaigns requiring forecasting and nowcasting support in a hybrid virtual/in-person framework.

54 ENVIRONMENTAL SCIENCES↗

UPF and Y-12 Criticality Accident Alarm System (CAAS) Radiation Testing Report

This report documents the experimental conditions and results for the testing of the Mirion Technologies CAAS-3S Criticality Accident Alarm System (CAAS) for the Y-12 National Security Complex (Y-12) and Uranium Processing Facility (UPF). The testing was conducted at the Godiva IV Burst Reactor at the National Criticality Experiments Research Center (NCERC) at the Nevada National Security Site (NNSS) during the week of January 11, 2021. The testing was conducted in accordance with 25774-QL-POA-JR00-00002-VDE-27.0, CAAS-3S Radiation Testing of Cabinet Components Test Plan. The tests subjected the CAAS-3S system to intense and short duration mixed neutron and gamma radiation fields and to high integrated radiation doses. The purpose of the test was to environmentally qualify various CAAS-3S components in a radiation environment. Successful completion of the tests was predicated on the collaborative efforts of several organizations. Sandia National Laboratory (SNL) and Lawrence Livermore National Laboratory (LLNL) provided dosimetry to estimate photon and neutron dose. Los Alamos National Laboratory (LANL) manages the NCERC facility, operated the Godiva IV reactor, and provided field support for CAAS-3S placement and communications interface for data acquisition systems supplied by Mirion Technologies. Throughout the test campaign, Y-12 and UPF personnel provided technical support in determining changes to the test schedule, as needed, interpretation of the results, and comparison between the measured dosimetry data and predicted results. Throughout the test campaign, Mirion personnel provided technical support in the operation of the CAAS-3S system itself.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

A Systems Engineering Approach to Accident Response Planning.

This paper explores the Systems Engineering structure, strategies and tools for real world scenarios involving work with accident response planning. A systems engineering approach must be taken by the technical teams to prepare for a successful response and design the technical systems in support of the operations. The scope of this project is focused on laying out the foundation of the systems engineering approach taken to help the teams develop an accident response strategy and identify new engineering designs in support of these operations for the black box systems. This Masters project involved several interdisciplinary teams & stakeholders. Identifying the proper tools to use was key to addressing the big picture needs of the multiple stakeholders. The integrated project work primarily took place over the course of eight weeks via integrated team meetings. Other work in support of this project was conducted off-line as needed by the project lead. Details on the prospective timeline, milestones, key dates and work scope can be referenced in this paper. Key systems engineering methodologies and tools used in support of this project included but is not limited to: Market Surveys and Interviews Project Charter Feasibility Study Swim Lane Diagram Knowledge Management Plan. A full suite of tools and the details regarding the application of these tools and results of this study is provided in this report.

42 ENGINEERING↗

EVs@Scale Next-Gen Profiles - Fleet Utilization 2023

As U.S. fleet operators begin transitioning to electric vehicles (EVs), critical questions arise regarding how to manage this shift without disrupting fleet operations or placing undue stress on the electric grid. A major challenge for fleets is maintaining effective operational schedules while accommodating charging requirements, particularly with high-power charging (HPC) infrastructure, which presents grid stability concerns for utilities. Proposed solutions such as charging substations, megawatt charging systems (MCS), and smart charge management systems (SCMS) offer potential pathways forward, but their effectiveness depends on alignment with real-world fleet behavior and operational constraints. This report investigates the charging and utilization behavior of EV and EVSE fleets actively employing HPC technologies by conducting detailed case study analyses based on telematics data. A suite of predefined metrics—covering charging, routing, and other operational behaviors—is developed to evaluate the impact of fleet activities on grid infrastructure and identify opportunities for optimization. Results highlight variations in charging behavior across fleets, such as weekday versus weekend usage, diurnal charging trends, and the role of operational predictability in enabling SCMS effectiveness. While SCMS can help lower costs and improve energy efficiency for fleets with stable schedules, they may be insufficient for fleets with highly variable or long-haul operations, which may require more robust solutions like MCS. Visualization of aggregated hourly energy metrics reveals that while fleet behaviors are diverse, there are common temporal patterns that could inform infrastructure planning and energy management. These insights emphasize the need for fleet-specific charging strategies that minimize grid impact while supporting reliable fleet operations. Additionally, the report underscores the broader economic stakes of electrification, particularly in high-value markets such as freight, where misaligned transitions could stall EV adoption. By examining current EV and EVSE fleet deployments using predetermined standardized metrics, this study offers a foundation for developing technologies and operational frameworks that support scalable, grid-compatible electrification across a variety of fleet types while establishing a baseline understanding of operational behaviors. In doing so, we aim to ensure that future charging solutions reflect actual fleet needs and grid constraints—an essential step toward maintaining operational continuity and achieving a successful transition to electric fleet operations.

Charging↗

A Systems Engineering Approach to Accident Response Planning

This paper explores the Systems Engineering structure, strategies and tools for real world scenarios involving work with accident response groups. A systems engineering approach must be taken by the technical teams to prepare for a successful response and design the technical systems in support of the operations. The scope of this project is focused on laying out the foundation of the systems engineering approach taken to help the teams develop an accident response strategy and identify new engineering designs in support of these operations for the black box systems. This Master’s project involves several interdisciplinary teams & stakeholders across different areas. Identifying the proper tools to use is key to addressing the big picture needs of the multiple stakeholders. This project explores some of the key tools used by the integrated team. The integrated project work will primarily take place over the course of 8 weeks via integrated team meetings. Other work in support of this project will take place off-line as needed by the project lead. Details on the prospective timeline, milestones, key dates and work scope can be referenced in other sections of this paper. Key systems engineering methodologies and tools used thus far in support of this project includes: 1) Market Surveys and Interviews, 2) Project Charter, 3) Feasibility Study, 4) Swim Lane Diagram, and 5) Knowledge Management Plan.

42 ENGINEERING↗

Operating a full tungsten actively cooled tokamak: overview of WEST first phase of operation

WEST is an MA class superconducting, actively cooled, full tungsten (W) tokamak, designed to operate in long pulses up to 1000 s. In support of ITER operation and DEMO conceptual activities, key missions of WEST are: (i) qualification of high heat flux plasma-facing components in integrating both technological and physics aspects in relevant heat and particle exhaust conditions, particularly for the tungsten monoblocks foreseen in ITER divertor; (ii) integrated steady-state operation at high confinement, with a focus on power exhaust issues. During the phase 1 of operation (2017–2020), a set of actively cooled ITER-grade plasma facing unit prototypes was integrated into the inertially cooled W coated startup lower divertor. Up to 8.8 MW of RF power has been coupled to the plasma and divertor heat flux of up to 6 MW m –2 were reached. Long pulse operation was started, using the upper actively cooled divertor, with a discharge of about 1 min achieved. This paper gives an overview of the results achieved in phase 1. Perspectives for phase 2, operating with the full capability of the device with the complete ITER-grade actively cooled lower divertor, are also described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Analytic Framework for Optimal Sizing of Hydrogen Fueling Stations for Heavy Duty Vehicles at Ports (CRADA 512)

This CRADA presents the strategy that PNNL and Sandia National Laboratories (SNL) will take to support Seattle City Light (SCL) in properly sizing a hydrogen station for class 8 drayage trucks at the Port of Seattle (Port), as part of a coordinated plan of mixed uses for hydrogen. The proper sizing for the fueling station is unique from past experiences because it will be part of a coordinated plan for a multi-use scheme for the hydrogen, and not a stand-alone fueling station. The multiple use-streams, and their relative values, will impact all facets of station sizing and design, including fueling rates, storage technology and size, equipment selection, and safety considerations. The future deployment of this fueling station, and its proper sizing, is seen as a critical first step in the larger vision of utilizing hydrogen to address a range of issues for SCL and the Port. These include, but are not limited to, large scale fueling of medium duty (MD) and heavy duty (HD) vehicles to reduce emissions, support of adjacent light duty (LD) vehicles, support of critical port operation during extreme events (e.g. resiliency), mitigation of capital intensive electrical distribution system upgrades to support evolving port operations, a market resource that can be used by SCL to generate revenue, and support of planned future maritime operations that currently require heavy use of shipboard hydrogen. While the broader use of hydrogen by SCL and the Port is not the focus of this CRADA, how its use impacts the design of the initial vehicle fueling station, and the modular approach, are the central work. As such, this project will develop the framework and process for developing a modular station design that considers the broader range of coordinate uses of hydrogen as an energy resource.

08 HYDROGEN↗

Emergency Diesel Generator Reliability and Installation Energy Security

The U.S. Department of Defense’s (DoD’s) fixed installations - or military bases - are a critical element of national security. Military bases support the maintenance and deployment of weapons systems, training and mobilization of combat forces, and provide direct support to combat operations. Fixed installations do not operate without energy and they rely largely on electricity to support critical missions and functions. Installations are dependent on a commercial grid that is vulnerable to disruption due to severe weather, physical attacks, and cyberattacks. This report looks at the impact on the highest priority critical loads.

24 POWER TRANSMISSION AND DISTRIBUTION↗

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Volume 9: Critical Facility with Add-On Ion Beam

Completion of the originally planned critical facility has been considered as part of the High Flux Isotope Reactor (HFIR) Sustaining and Enhancing Neutron Science Initiative at Oak Ridge National Laboratory (ORNL). A working group of ORNL staff members was formed to develop the idea and to recommend one or more configurations to best support future HFIR operations and scientific capacities. HFIR was designed with a critical pool in the reactor bay that was projected to be outfitted as a critical facility. The primary purpose of the planned critical facility was to measure the subcritical worth of fresh fuel elements to support startup requirements. However, the Y-12 National Security Complex already housed a critical facility that was used for this purpose. This report presents the working group’s efforts, including determination of the proposed critical facility’s high-impact benefits. A generic low-power critical facility would be employed for reactor physics measurements, code and data validation, reactor operator and staff training, and education. This facility would be instrumental in supporting current HFIR operations, conversion of HFIR to low-enriched uranium, existing light water reactor operations, and advanced reactor development and deployment.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of Whole System Digital Twins for Advanced Reactors: Leveraging Graph Neural Networks and SAM Simulations

Here, in this work, we introduce a novel method to develop whole system digital twins (DTs) for advanced nuclear reactors. This method treats a complex reactor system as a heterogeneous graph: with the system components as different types of graph nodes and their physical interconnections as edges. Based on the heterogeneous graph, a graph neural network combining graph convolution and temporal node attention is developed as the DT, facilitating a comprehensive understanding of the system's dynamic behavior. By utilizing the System Analysis Module (SAM) code for simulating various operational transients, we develop a graph-based database that trains the DT. This DT is characterized by two primary functions: It can infer the entire system's status using sparse node information, and it can predict the progress of transients based on current and historical system information. Our approach is validated through case studies on the Experimental Breeder Reactor II (EBR-II) system and a generic Fluoride-salt-cooled High-temperature Reactor (gFHR), demonstrating the DT's accuracy in forecasting operational transients. The DT's rapid computation capabilities enhance its potential for supporting advanced reactor operations, offering benefits in intelligent simulation, autonomous control, and anomaly detection, paving the way for improved safety analysis and intelligent component health management for advanced reactor systems and reducing their operations and maintenance cost.

EBR-II↗