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DOE OSTI2022

SULI Research Report

Acoustic levitation allows for the containerless manipulation of small samples limited by density, size, and shape. Modern acoustic levitators are either constructed with Langevin horns, which need to be machined to high tolerance and require at least 100V, or ultrasonic transducers, which are robust to changes in temperature and require low voltage. We investigated the ability of the TinyLev, a commercially available single axis levitator, and prototyped a two-axis levitator. Both the TinyLev and our two-axis levitator employ phased arrays of transducers and operate at 40 kHz. Models produced with the Python toolbox Levitate showed the characteristic nodes of the TinyLev and found two previously unpublished “traps” (stable local pressure minima) of the twoaxis levitator. We plan to use these levitators at the Advanced Photon Source (APS) to study a variety of samples, via white beam diffraction and high speed imaging. It is our goal to calculate the radial distribution function with respect to temperature across phase transitions.

42 ENGINEERING↗

DOE OSTI2021

Report on High Energy Arcing Fault Experiments: Experimental Results from Open Box Enclosures

This report documents an experimental program designed to investigate High Energy Arcing Fault (HEAF) phenomena. The experiments focus on providing data to better characterize the arc to improve the prediction of arc energy emitted during a HEAF event. An open box experiment allow for direct observation of the arc, which allows diagnostic instrumentation to record the phenomenological data needed for better characterization of the arc energy source term. The data collected supports characterization of the arc and arc jet, enclosure breach, material loss, and electrical properties. These results will be used to better characterizing the hazard for improvements in fire probabilistic risk assessment (PRA) realism. The experiments were performed at KEMA Labs located in Chalfont, Pennsylvania. The experimental design, setup, and execution were completed by staff from the NRC, the National Institute of Standards and Technology (NIST), Sandia National Laboratories (SNL) and KEMA Labs. In addition, representatives from the Electric Power Research Institute (EPRI) observed some of the experimental setup and execution. The HEAF experiments were performed between August 22, 2020 and September 18, 2020 on near-identical 51 cm (20 in) cube metal boxes suspended from a Unistrut support structure. The three-phase arcing fault was initiated at the ends of the conductors oriented vertically and located at the center of the box. Either aluminum or copper conductors were used for the conductors. The low-voltage experiments used 1 000 volts AC, while the medium-voltage experiments used 6 900 volts AC consistent with other recently completed experiments. Durations of the experiment ranged from 1 s to 5 s with fault currents ranging from 1 kA to 30 kA. Real-time electrical operating conditions, including voltage, current and frequency, were measured during the experiments. Heat fluxes and incident energies were measured with plate thermometers, radiometers, and slug calorimeters at various locations around the electrical enclosures. The experiments were documented with normal and high-speed videography, infrared imaging and photography.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

2022 Peer Review Project Summary: Advanced Protection for Microgrids and DER in Secondary Networks and Meshed Distribution Systems

Although there are increasing numbers of distributed energy resources (DERs) and microgrids being deployed, current IEEE and utility standards generally strictly limit their interconnection inside secondary networks. Secondary networks are low-voltage meshed (non-radial) distribution systems that create redundancy in the path from the main grid source to each load. This redundancy provides a high level of immunity to disruptions in the distribution system, and thus extremely high reliability of electric power service. There are two main types of secondary networks, called grid and spot secondary networks, both of which are used worldwide. In the future, primary networks in distribution systems that might include looped or meshed distribution systems at the primary-voltage (mediumvoltage) level may also become common as a means for improving distribution reliability and resilience. The objective of this multiyear project is to increase the adoption of microgrids in secondary networks and meshed distribution systems by developing novel protection schemes that allow for safe reliable operation of DERs in secondary networks. We will address these challenges by working with the appropriate stakeholders of secondary network operators, protection vendors, and standards committee. The outcomes of this project include: a) development and/or demonstration of candidate methods for enabling protection of secondary networks containing high levels of DER; b) development of modeling and testing tools for protection systems designed for use with secondary networks including DERs; and c) development of new industrial partnerships to facilitate widespread results dissemination and eventual commercialization of results as appropriate.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

High Temperature Optocoupler for 3D High Density Power Modules

The goal of this proposed research is to develop a reliable high-temperature optocouplers, which can operate at 250°C with at least ten-year lifetime, and replace isolation transforms as the galvanic isolation solution for the 3D integration of high density power modules. The electrification of future transportations (i.e., electric vehicles) will continuously drive the demand for high density power modules. Optocouplers (i.e., packaged light emitter and detector) as a promising candidate to replace bulky isolation transformers are highly desirable to facilitate the continuous scale-down of gate driver circuitry that will lead to 3D high density power modules and achieve disruptive performance in terms of thermal management, power density, power efficiency, reliability and operating environments. However, regular semiconductor optoelectronic materials and devices have significant difficulty functioning in the harsh environments designated for high density power module usage (such as operation at high temperatures). Ultimately, it is not the intrinsic properties of power devices that prevent their use at higher temperatures, but rather the low voltage electronics needed to drive them and the packaging that surrounds them. The typical operating temperature for optocouplers is only up to 100°C, due to the limitations of light emitting diode (LED) devices inside and packaging materials. A systematic characterization methodology will be developed to analyze the performance, lifetime and reliability of LED devices and distinguish multiple failure mechanisms at high temperatures. An original methodology of “design for reliability” will be developed to design the optoelectronic devices with high reliability and long lifetime at high temperatures. A new architecture of high temperature high reliable optocouplers will be developed, fabricated and demonstrated with continuous operating at 250°C. The development of efficient, reliable high density 3D power modules is the foundation for energy efficiency and energy reliability. Enabled with advanced 3D integration and packaging technologies, high density power module solutions can achieve much more superior performance over the conventional discrete solutions in terms of efficiency, thermal management and power density. The proposed concept of high temperature optocouplers as the galvanic isolation solution for high density power modules will bring together interdisciplinary research involving the wide bandgap materials, optoelectronics, high reliable device design, electronics packaging and power modules. A streamline of skilled personnel would be trained including graduate and undergraduate students, local engineers and scientists which are in great demand to both academia and optoelectronics industry. The proposed research topics, such as, solid state lighting and high temperature device reliability, are currently of major interest at the Department of Energy, in particular, Sandia National Laboratories. This project can enhance collaborations between the University of Arkansas (UA) and Sandia National Laboratories. The findings of the proposed research are expected to be integrated into high density 3-D power modules at the Engineering Research Center for Power Optimization for Electro-Thermal Systems (POETS).

42 ENGINEERING↗

DOE OSTI2022

Extension of Cable Electrical Assessment Techniques to Detect and Discriminate Radiation Aging on Cable Insulation Systems (Abstract)

The purpose of this study of the electrical responses of gamma radiation aged low voltage nuclear cables is to advance tools to determine cable condition (extent of damage) and identify degradation location along the cable length. The developed technology will provide nuclear plant operators with the options to focus cable repair, mitigation, or replacement efforts locally and avoid wholesale cable replacement.

42 ENGINEERING↗

DOE OSTI2022

The Demonstration of Power over Ethernet (PoE) Technologies in Commercial and Institutional Buildings

Power over Ethernet (PoE) technologies are currently ubiquitous in offices in the form of phones, access points, and IP security cameras. They are systems that are familiar to and managed by on-site IT staff. As low voltage DC-power capabilities have increased with the advancement of IT network switches within offices, PoE devices are now being integrated across additional building systems, including lighting, computers, and HVAC controls. The connection of PoE devices to network switches offers the opportunity for energy monitoring and management to be performed through IT network management software. Data and results from technology validations of PoE equipment remain very limited. This lack of information hinders expansion of PoE as an energy management strategy as its benefits and challenges have been insufficiently quantified in real-world scenarios. This final report presents the findings of a DOE/State of Minnesota-funded project that demonstrated and assessed the energy and non-energy benefits of Power over Ethernet (PoE) technologies at six sites: two offices, three schools, and a hotel. The goals of the demonstrations were to: (1) assess the receptiveness of commercial and institutional markets to these new technologies, (2) demonstrate the feasibility of PoE technologies within standard design/construction practices and commercial codes, (3) assess the energy and cost savings opportunities of these technologies, (4) provide energy management opportunities where not typically available, and (5) formulate approaches to spur adoption of these technologies in the marketplace.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Dual Triggered Beam Extraction Kicker (Rev. 1)

A Blumlein modulator is a relatively inexpensive pulsed power device that can deliver highly repeatable pulses that can be used to change the path of beam pulses. The modulator is primarily built with transmission line cable which is relatively inexpensive. Due to the highly repeatable nature of a Blumlein modulator it is a great tool for kicking beam pulses while producing very little spill or losses in beam current. One of the challenges with a Blumlein kicker is that the length of the kicking pulse output by the modulator is determined by the length of the cables. Cable lengths are set prior to implementation for the desired kicking pulse width. The Blumlein modulator at LANSCE uses a single thyratron which can deliver two 50-kilovolt 1,000-amp pulses of opposite polarity to kicking plates at the same time. This method makes for a very strong kick that is highly repeatable. A method that has been discussed, to deliver a different pulse width, is to add a second trigger that would be fired, once the desired pulse width has been delivered, cutting out the remaining pulse. The second trigger would offer a lot of variability with the pulse width of the kicker. This method has only ever been attempted using low current and relatively low voltages compared to the scale needed to properly kick a beam pulse. This in turn allows for the use of power supplies with a higher repetition rate. The advancement of this standard kicker technology in the accelerator facilities would attract attention within the scientific and engineering communities. The project detailed within will investigate the capabilities of different triggering topologies and design a prototype dual triggered Blumlein kicker modulator capable of variable kicking pulse width.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Control Carrier Board (CCB) Damage (ISS-95470.01)

CCBs installed in the first LRU32 preproduction units were found to not operate properly when received at LLNL from the integration vendor on 02/07/2023 during integrated testing of low voltage and high voltage as the first steps of validating a functional LRU for physics qualifications. CCB version dated 12/10/2021 was found to not accommodate a design change approved 09/28/2022 , which led to damage occurring during testing. The test stand holding pins would interfere with the location of a resistor due to CCB design modification and pressed on the resistor causing damage. Communication deficiency is identified as cause of issue.

42 ENGINEERING↗

DOE OSTI2024

Field Emission Current Transfer for Homopolar Machines

With the increasing electrification of transportation, the need for high power density electric machines is higher than ever. The required specific power for the more demanding applications, such as airplane propulsion, is over 20 kW/kg for multi-megawatt range power levels. Fully superconducting synchronous machines could reach the required performance, but significant challenges remain to be addressed such as AC losses management and rotating cryogenics implementation. Homopolar machines constitute the simplest electro-mechanical conversion systems possible, however the difficulty of establishing reliable and efficient low voltage, high DC current transfer from a stationary to a rotating system has prevented homopolar machines from competing with AC electrical machines. While sliding contacts or liquid metal contacts are feasible, they lead to high losses, high maintenance requirements and the use of environmentally unfriendly materials. We investigated field emission current transfer as an alternative to sliding contacts. We have demonstrated field emission current transfer in vacuum between a copper electrode and carbon nanotubes and diamond pyramids to evaluate the feasibility of contact-free current transfer for homopolar machines. The initial field emission testing was successfully demonstrated with current densities in the 10 mA/cm 2 range. The initial experiments validated the concept and supported the development of a roadmap for the development of contactless current transfer for homopolar machines, helped understand the limitations of the current test system and identify the key parameters that will lead to better performance.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Low-Cost, Easy-To-Integrate and Reliable Grid Energy Storage System with 2 nd Life Lithium Batteries

Batteries retired from electric vehicles have the potential to extend their service as low-cost stationary energy storage systems. However, disperse battery state of health (SOH) and nonuniform battery characters often lead to compromised battery performance and reliability, which greatly hinder their adoption. A Heterogenous Unifying Battery (HUB) system is proposed to stage 2 nd life battery bricks for a period, and enable them to attain improved SOH uniformity, performance, and reliability before being sold for 2 nd life applications, while simultaneously providing grid services. It may offer a technically and economically advantageous solution for the broad utilization of 2 nd use batteries. The goal of this project was to develop the hardware and software that enables the key functions of the HUB system. The first achievement of the project was the development of a 1kW scale proof-of-concept (POC) system, which comprises (i) a modular plug-n-play DC-DC power converter matrix with isolated series output connections to achieve fully independent control of energy flow to each of the connected battery units at low voltage; (ii) enhanced model based control that drives each batteries’ SOH towards uniformity while collectively providing grid energy storage services; and (iii) comprehensive procedures to perform battery diagnostics and prognostics. The second achievement was the development of a 100kW scale HUB system and demonstrated its performance of re-establishing battery SOH uniformity through a period of battery cycling operation. The final HUB system incorporates six DC-DC power converter matrices paired with six battery bricks. Hot swapping of a single battery brick while maintaining consistent system power was demonstrated and system operation was validated to be capable of implementing the approved grid duty cycle and of balancing and conditioning the battery bricks. Through the course of the project, the team optimized the building-block design, form-factors, and adjusted life balancing control. An up-sized 250kW Scale was developed and deployed in October 2022 with pack-level battery form factors, see photo in Figure 1 The third achievement of the project was to perform a techno-economic analysis in order to better understand the cost and revenue potentials in this new “recondition-then-resell" value proposition. The final TEA quantified the economics of new Li-ion batteries as well as second-life batteries processed via reconditioning and traditional binning. Results showed the reconditioned second-life batteries in this project to be economically favorable and viable in grid energy storage markets. The TEA results were published in the Applied Energy journal. The fourth achievement of the project was to deliver a tech-to-market plan for the HUB system that includes funding, IP, and manufacturing strategies. The final T2M plan outlines a business strategy in which the HUB provides a B2B service to EV companies as an alternative to battery recycling that can prepare batteries for 2nd life applications. A company named Smartville Inc. was founded to carry on the commercialization, funding, and technical IP licensing activities of the OPEN project.

25 ENERGY STORAGE↗

DOE OSTI2024

Determining Optimal Running Conditions for TinyTPC Detector

Liquid argon time projection chambers, (LArTPCs), are particle detectors used to collect ionization charge information from particle trajectories, facilitating detailed particle track analysis. They are currently used as particle detectors in major physics projects such as the deep underground neutrino experiment (DUNE), to detect and study the nature of the elusive neutrino particle. TinyTPC is a small scale LArTPC featuring a pixelated readout system (LArPix) that we will use to study liquid argon doping. We expect this doping to enhance the resolution of LAr detectors, especially for low energy particles below 10 MeV which would expand the capabilities of currently running experiments. Housed within a cryostat filled with liquid argon, the TinyTPC will rely on a high and a low voltage system to collect data. In preparation for deployment we found and resolved issues in the HV and LV systems and we determined optimal running conditions in a test vessel. This presentation will go over the detector commissioning process that enabled data taking with the TinyTPC.

Gonzalez, Rebecca↗

DOE OSTI2021

Electropotential Verification for Nuclear Safeguards

The international safeguards regime desires methods to efficiently verify that facilities are only performing declared activities. Electropotential verification (EPV) is a newly proposed technique that was tested for its feasibility to perform facility design information verification (DIV). EPV works by passing a constant, low voltage current through a conductive system (facility infrastructure of nuclear fuel assembly) and measuring the resulting voltage at various places throughout the infrastructure in order to establish a baseline. Changes made to the system affect these voltage readings, which will deviate from the baseline and indicate that a change to the system was made. For large scale infrastructure such as a nuclear facility DIV, it appears feasible that changes in configuration of the system’s grounding can be detected in real-time, and the location of the change can be inferred from the measured intensity of the change in voltage.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2023

Electropotential Verification for Nuclear Safeguards

The international safeguards regime desires methods to efficiently verify that facilities are only performing declared activities. Electropotential verification (EPV) is a newly proposed technique that was tested for its feasibility to perform facility design information verification (DIV) and verification of spent nuclear fuel while in a cooling pool. EPV works by passing a constant, low voltage current through a conductive system (facility infrastructure of nuclear fuel assembly) and measuring the resulting voltage at various places throughout the infrastructure in order to establish a baseline. Changes made to the system affect these voltage readings, which will deviate from the baseline and indicate that a change to the system was made. For facility DIV, it appears feasible that changes in configuration of the system’s grounding can be detected in real-time, and the location of the change can be inferred from the measured intensity of the change in voltage. Determination of whether or not spent fuel was present in a fuel rod, as well as the presence/absence of a fuel rod from an assembly using EPV, proved unsuccessful with the sensitivity of instrumentation used in this study.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Spread Spectrum Time Domain Reflectometry (SSTDR) and Frequency Domain Reflectometry (FDR) for Detection of Cable Anomalies Using Machine Learning

Cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Advanced Protection for Microgrids and DER in Secondary Networks and Meshed Distribution Systems

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

SSTDR and FDR Detection of Un-Energized and Energized Cable Anomalies Including Thermal Degradation Using Machine Learning

Historically, cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages. A related technology that has found some acceptance in the aircraft and rail industry is spread spectrum time domain reflectometry (SSTDR). This technology has been implemented with a custom commercial instrument by LiveWire Innovation that is designed to operate on live cables up to 1000 volts and with a bandwidth of 48 MHz. Initial evaluation by the Pacific Northwest National Laboratory (PNNL) of the Live Wire system indicated that a broader bandwidth (BW) SSTDR may be better for many kinds of flaws. This led PNNL to develop an SSTDR laboratory instrument suitable for tests up to 500 MHz bandwidth. Testing on energized cables is also desirable for online monitoring systems so an inductive clamshell coupler was developed that allows energized cables to be tested up to at least 5 kV and likely higher voltage levels. Dielectric spectroscopy and tan delta testing plus various laboratory destructive tests were included in this data acquisition campaign directed to feed a machine learning (ML) study. With these kinds of developments, online energized cable tests may be possible with industrial adoption of such hardware advances but it will be completely impractical to have highly skilled data analysts continually examine these complex signals for indications of damage or compromised conditions. If online testing is to be implemented in new test hardware, it must be accompanied by software that can interpret the signals and alert plant operators of changing or degraded conditions. The thermally aged, shielded cable investigated here was separately treated for ML analysis. Visual analysis of electrical data showed generally increasing peaks where the cable entered and exited the oven. These peaks were not exactly aligned with expected locations, but these differences were attributed to velocity of propagation calibration errors. Only supervised ML was applied to the thermally aged data as this data was only available shortly before the committed publication date of this report. The supervised ML was structured to divide the 0 to 70-day responses as ‘normal’ from 0 to 35 days or ‘anomalous’ from 36 to 70 days, based on cable tensile elongation at break (EAB) insulation characterization. Using 80% of the data for training and 20% for testing, the supervised ML predicted normal versus anomalous was 70% accurate. Important conclusions include: • Accuracy to predict the presence of cable damage is improved from the 2023 effort by more training data. Weighted accuracies for comparisons among the instruments ranged from 67 to 89 % for unsupervised ML and 71 to 99% for supervised ML. • Based on the synthetic data tests, the unsupervised models are more generalizable to unseen anomalies. The Multi-Layer Perceptron classifier (MLP) model reported as high as 99.7% accuracy on the test data, but this dropped to 58.3% when tested on the synthetic data. In contrast, the unsupervised Pointwise model only achieved 89.7% accuracy on the experimental data but reported 78.3% accuracy on the synthetic data. • The best anomaly indicators are higher frequency (400 MHz BW) FDR data. Other tests may be interesting but for this study, this was the best predicter.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

SSTDR and FDR Detection of Un-Energized and Energized Cable Anomalies Including Thermal Degradation Using Machine Learning

36 MATERIALS SCIENCE↗

DOE OSTI2025

Real-Time Testbed for Smart Grid Recloser Controller

The growing need for a low voltage recloser has become apparent due to the rise in requirements for a smart grid. This includes more detailed management of power flow forward (towards load) and backward (towards generation), source synchronization in real time, more indepth fault responses, and the use of green energy. The SEL-651R-2 relay is a device that can manage these needs, especially in fault response and synchronization, and is commonly used in systems called microgrids. Microgrids are distribution level systems that are able to operate separated from the main grid, are typically installed much closer to the load(s), and are fed by distributed energy resources (DERs), such as wind, solar or diesel generators. The SEL-651R-2 is normally used in the field with presets operative settings, but the Western Michigan University (WMU) Center for Interdisciplinary Research on Secure, Efficient and Sustainable Energy Technology (WMU InterEnergy Center) wished to test this device in its range of capabilities for microgrid application. A Hardware-In-the-Loop (HIL) testbed was implemented and used through the Real Time Digital Simulator (RTDS) using the RSCAD software to test the SEL-651R-2's use cases and functions. The testbed includes a microgrid with interconnection to a larger main grid, and the relay is meant to control the recloser at the point of common coupling (PCC) between the main grid and microgrid. The testbed shows how basic protections, reclosing, and synchronization checks function when handling faults that affect both the microgrid and the main grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗