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Divertor Plasma Detachment Control Neural Network
DivControlNN is a state-of-the-art software tool that leverages advanced machine learning techniques to predict and control divertor plasma behavior in fusion reactors. Plasma, a highly energetic and electrically charged gas, requires meticulous management to protect reactor components and maintain optimal energy production. Conventional simulation methods, although extremely detailed, typically demand extensive computational time-making them unsuitable for real-time control scenarios. DivControlNN addresses this challenge by learning from tens of thousands of high-fidelity simulations, thereby creating a rapid surrogate model that can deliver near-instantaneous predictions. At the core of its functionality is a sophisticated technique known as latent space mapping, which condenses complex, high-dimensional plasma data into a compact, lower-dimensional representation. This streamlined representation enables the system to quickly forecast essential plasma properties and determine the precise conditions required for effective detachment. Detachment is a crucial process in which the plasma is cooled before reaching the divertor plates, thereby reducing heat loads and mitigating material erosion. In recent experiments conducted on the KSTAR tokamak in South Korea, DivControlNN successfully guided the detachment process without any fine-tuning-even when applied to a new tungsten divertor configuration. By achieving a computational speed-up of over one hundred million times compared to traditional simulation methods while maintaining low prediction errors, DivControlNN stands to significantly enhance real-time control and diagnostic capabilities in future fusion reactors. This breakthrough paves the way for safer, more reliable reactor operation and represents a major advancement toward realizing fusion energy as a practical, sustainable, and clean power source.
High Voltage Multiplier: A New, Compact Design using SiC High Frequency MOSFETs
In this report, power supply models for particle accelerators are examined and electrical equivalent model for a high-voltage multiplier power supply is developed. The ultimate goal is to provide the blue prints for the realization of real world models to power both the electrical and magnetic dipoles that make up the key components of the typical particle accelerator assembly.
An Operations and Maintenance Roadmap for U.S. Offshore Wind: Enabling a Cost-Effective and Sustainable U.S. Offshore Wind Energy Industry Through Innovative Operations and Maintenance
The United States is currently targeting 30GW of offshore wind to be installed by 2030, and 150GW by 2050. Even considering future turbine sizes, this represents thousands of new turbines installed in a diverse set of environments, each with their unique design, installation, and maintenance challenges. While much can be learned from European and Asian experience with offshore wind over the past two decades, it is important to understand the unique circumstances of the U.S. This document explores operations and maintenance of offshore wind energy, specific to the U.S. and attempts to lay out a roadmap for needed activities to ensure reliability of future installations. The roadmap was informed through dozens of interviews with a wide cross-section of the industry, including representatives from OEMs, owner/operators, service companies, certification agencies, service providers, and researchers. The roadmap first describes the problem by component - blades, drivetrain and nacelle, structures and foundations, and electrical systems - through a look at current practices and opportunities for improvement in the areas of Failure Mode Analysis and Mitigation; Monitoring, Sensing, and Inspection; and Maintenance Execution. Crosscutting areas of Digitalization, Robotics and Automation, Prognostics and Health Management and O&M Optimization, Experimentation and Demonstration, Standardization, and Design Optimization Considering Reliability and O&M are then discussed. Finally, the roadmap summarizes all of these topics with recommendations for short (1-3 years), medium (4-7 years), and long term (8-12 years) activities, with a description of needed public and private sector contributions.
Preliminary System Interface Failure Mode Analysis for Two Advanced Reactors
This study explores two distinct Balance of Plant (BOP) configurations: the Rankine cycle for a sodium-cooled fast reactor (SFR) and the Brayton cycle for a gas-cooled reactor (GCR). As representative designs, the Power Reactor Innovative Small Module (PRISM) by GE Hitachi Nuclear Energy was selected for the SFR, while the Gas Turbine Modular Helium Reactor (GT MHR) by General Atomics was chosen for the gas-cooled reactor. Both configurations were adapted to deliver high-quality heat for industrial applications. A Failure Modes and Effects Analysis (FMEA) was conducted for each system to identify critical failure modes affecting key components. This study marks the first phase of a two-step design optimization approach, integrating FMEA into the design process. Based on the analysis, design modifications and mitigation strategies were proposed to enhance system resilience. The second phase, to be detailed in a subsequent report, will focus on the role of the control system in mitigating these failures. The FMEA serves as a foundation for defining the control topology, ensuring system resilience against component failures that could compromise essential functions, such as electricity and heat production.
ORNL Hydropower Cost Database Extract from FERC Form-1
The ORNL FERC Form 1 Hydropower Cost Database Extract is a cleaned and compiled version of the hydropower component of the Federal Energy Regulatory Commission’s (FERC) Electric Utility Annual Report, also known as Form-1. The database includes conventional and pumped storage hydropower plants owned by non-federal major utilities that submitted the Form 1 data from 1994-2020, representing about 22% of existing conventional hydropower capacity and 61% of pumped storage capacity. The database includes the escalation factors and describes the methods used to scale costs to a common data year, as well as tables of identifiers necessary to link the hydropower plants to two other relevant databases, the National Inventory of Dams and the ORNL Existing Hydropower Assets database. This database provides historical capital and operating costs for three schedules/classes defined in Form 1: Large Hydro, Pumped Storage Hydro, and Small Hydro. The Large Hydro and Pumped Storage Hydro data include cost items, such as land, structures, facilities, etc.
Transformer Health Monitoring Using Dissolved Gas Analysis
As integral components of any power plant, transformers supply the generated electricity to the grid. However, a transformer’s cellulose-based paper insulation and the mineral oil in which it is immersed break down over time under standard operating conditions—or more rapidly due to potential faults within the system. As the transformer’s mineral oil breaks down, gases are released that can be measured and monitored. This technical brief exhibits a collection of diagnostic and prognostic techniques that utilities can adopt in lieu of labor-intensive periodic preventive maintenance routines. Furthermore, prognostic models have been incorporated using the latest version of the Institute of Electrical and Electronics Engineers (IEEE) standard (IEEE, 2019) for dissolved gas analysis (DGA), thus expanding it to include estimation of the time to maintenance. Overall, four different methodologies are explained, each of which aids in determining a transformer’s state of health. These methodologies include the Chendong model, the IEEE thermal life consumption model (IEEE, 2012), a diagnostic model for DGA, and a prognostic model for DGA that uses an autoregressive integrated moving average (ARIMA) model. An additional improvement for estimating missing system parameters by using monitoring data (i.e., a tool for parameter estimation utilizing Powell’s method) is presented, enabling the IEEE thermal life consumption model to benefit not only the collaborating power plant, but also the power industry at large.
Concentrated solar photovoltaic and photothermal system
The present invention provides a hybrid, concentrating photovoltaic-solar thermal (CPV/T) system and components thereof, and methods for converting solar energy to electricity at high efficiencies while capturing and storing solar thermal energy for later deployment.
A Data Processing Pipeline To Extract A Knowledge Graph From Sec Documents For Socio-technical Analysis Of Critical Infrastructure Influence
The code is written in Python and consists of the following pipeline that is implemented in Apache Airflow. This pipeline intends to understand the companies that are directly or indirectly involved with a type of critical infrastructure system at some point in that system's lifecycle. The pipeline takes a configuration file that specifies a list of initial companies to consider, a geographic region of interest (disk) expressed as a latitude/longitude point and distance, and a set of SEC form types from which to extract entities and relations. There are three main components to this pipeline as currently implemented: Social Network Extraction, Critical Infrastructure Network Extraction, and Inference and Fusion. First, Social Network Extraction, implemented as the `organizations_sec` component of the workflow graph queries the SEC EDGAR webservice using the list of initial companies from the configuration file. Given this, it extracts metadata that documents the number of each type of form for the given set of companies and their location. This forms metadata represents a catalog of data sources for the extracted social network knowledge graph. The pipeline then downloads these forms from the website and saves them in a build directory for further processing. These documents are then parsed for entities and relations. Second, the Critical Network Extraction component extracts entities and relations for a critical infrastructure sector. Currently, we focus on Electric Vehicle charging stations and this information is available via the Department of Energy (DOE) database on fueling stations maintained by NREL. Third, the Inference and Fusion component relates the social network graph to the critical infrastructure graph in order to understand the impact of a company within a geographic region. Relations include ownership of the EV Charging Station asset as well as maintenance/ownership of the EV payment networks. The fused network can be represented in many ways and currently we emit a knowledge graph.
Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales
Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.
Circuit Modelling of the Mechanical-Motion-Rectifier for Electrical Simulation of Ocean Wave Power Take-off
As is the case with several other mechanical power takeoffs (PTOs), the mechanical-motion-rectifier (MMR) based PTO consists of components such as one-way clutches, gears, a ball screw, mechanical couplings, and a generator. Equivalent circuit models have been created in this paper to describe the dry frictions, viscous damping, and mechanical compliances in these components, so the non-ideal efficiency and nonlinear force of the PTO can be predicted in electrical simulations by integrating these sub-circuit models. The circuit model is simplified, and its parameters are categorized as dc and ac unknowns. The dc and ac tests on the PTO are performed sequentially to extract two sets of parameters through linear regression or nonlinear curve fitting. Then, the model is validated through its prediction capability over 25 test conditions on input forces, output voltages, and efficiencies, with correlation coefficients of 0.9, 0.98, and 0.981, respectively.
Correlation Between Weather Alerts and Grid Component Failures for Grid Alert
Weather events cause most grid failures. Often, we even get notifications on our phones to take cover or be prepared for an imminent event. If electric grid utilities had a similar warning that also included probable scenarios and the equipment involved, they could prepare and minimize the effects. Recent research at Idaho National Laboratory into electric grid risk analysis methods resulted in a tool that allows for the development of the most likely scenarios given failure probabilities of grid components. INL has a project with the U.S. Department of Energy’s Cybersecurity, Energy Security, and Emergency Response (CESER) program to develop a Grid Alert application that receives messages from the existing emergency alert system, filters and determines components possibly affected by the emergency event, calculates probable scenarios uses MASTERRI and then notifies the utility if there is significant risk. Historical failure data of elements that comprise the U.S. electric grid have been compiled by utilities and organizations such as the international regulatory body North American Electric Reliability Corporation (NERC). Nominal failure rates are obtained from this data. To make this tool possible, estimated failure rates are needed for different component types given the alert type, severity, and location. Historic weather-related grid element failures are correlated with historic weather events from Integrated Public Alert & Warning System (IPAWS). These correlated events and failures are used along with Bayesian updates from the historical norms to provide a modified failure rate for grid elements in the alert areas and calculate probable scenarios. This discusses the Grid Alert project plan but focuses on the data gathered and process used in determining failure rates for possible grid failure scenarios.
Valuing Maintenance Strategies for Fusion Plants as Part of a Future Electricity Grid
Scheduled maintenance is likely to be lengthy and therefore consequential for the economics of fusion power plants. The maintenance strategy that maximizes the economic value of a plant depends on internal factors such as the cost and durability of the replaceable components, the frequency and duration of the maintenance blocks, and the external factors of the electricity system in which the plant operates. Here, this paper examines the value of fusion power plants with various maintenance properties in a decarbonized United States Eastern Interconnection circa 2050. Seasonal variations in electricity supply and demand mean that certain times of year, particularly spring to early summer, are best for scheduled maintenance. Seasonality has two important consequences. First, the value of a plant can be 15% higher than what one would naively expect if value were directly proportional to its availability. Second, in some cases, replacing fractions of a component in shorter maintenance blocks spread over multiple years is better than replacing it all at once during a longer outage, even through the overall availability of the plant is lower in the former scenario.
Hazard and risk analysis framework for nuclear power plant–based integrated energy systems
Employing integrated energy systems (IESs) with nuclear power plants (NPPs) can improve NPP utilization by leveraging dedicated thermal and electric power delivery, but it may also increase operational safety risks. This paper presents a framework to identify and quantify hazards and risks for such IESs. The framework combines accidentology to review past industrial accidents with failure modes and effects analysis (FMEA) to identify potential future incidents. Hydrogen explosion and toxic chemical release hazards are of particular concern. Explosion consequences are quantified using the Bauwens-Dorofeev (Bauwens) and trinitrotoluene equivalent mass (TNT-EM) methods, while chemical release consequences are computed using the Gaussian atmospheric dispersion method. Operational disturbances from direct electrical and thermal integration that may affect NPP safety are modeled using probabilistic risk analysis (PRA). Hazards and risks are then evaluated for regulatory compliance. The framework is applied to IESs comprising pressurized or boiling water reactors supplying three levels of thermal and electrical power to industrial customers. Case studies include high-temperature steam electrolysis hydrogen plants of varying capacities and a synthetic fuel production plant. Sensitivity analysis examines piping component failures in the PRA model as a precursor to cost estimation for thermal extraction line design. Additionally, Fussel-Vessely (FV) and risk increase importance (RII) measures identify risk-informed design improvements for the thermal extraction system. FMEA highlights hazards such as loss of offsite power, prompt loss of electrical load, loss of thermal output, and immediate steam diversion, in addition to hydrogen explosions and toxic chemical releases. Both Bauwens and TNT-EM methods suggest maintaining several hundred meters of separation between the NPP and hydrogen facility to mitigate explosion risks. PRA results show a maximum initiating event frequency increase of 1.15% and an overall risk increase of 0.28%. Importance measure analysis identifies upstream pipe leak isolation components as critical. Evaluating the results against safety regulations, it is concluded that hazards and risks can be managed to comply with regulations through risk-informed thermal and electrical connection designs, component selection, maintenance programs, and safe separation distances between NPPs and integrated industrial facilities.
Three and Two Phase Rotating Field Inductive Couplers for Wireless Power Transfer with One Phase per Layer Windings
Multiphase inductive wireless charging coils have been proposed recently to improve coupler surface power density, reduce component stress and size, and provide near-constant power delivery to charge mobile electric systems. Several aspects for the fundamental characterization of multiphase coils are explored up to six phases including approximate mutual inductance with size and turn variation, induced voltage, and output power estimation. The relative component stress and size of passive components for resonant operation are compared between the multiphase variants. A combination of an experimentally validated 3D electromagnetic finite element analysis (FEA) and power electronic co-simulations are used to validate the estimated quantities approximated with a mixture of analytical equations and an artificial neural network model for mutual inductance. A novel three-phase transmitter, two-phase receiver coil pair is also proposed for electric vehicle charging to reduce the number of connections and compensation complexity on the vehicle-side with improved power output compared to a two-phase configuration.
Competitiveness Metrics for Electricity System Technologies
The relative economic competitiveness of power generation technologies is a topic of much interest to diverse electric industry participants. However, assessing competitiveness can be challenging as it requires considering both total costs and total system value of each technology, which are complicated by the (1) numerous and diverse grid services needed to operate a reliable power system; (2) variations in the economic value of the grid services with system state and location, and over multiple timescales, due to the challenges of transporting and storing electricity; and (3) the unique characteristics of different electric system assets. Ideally, metrics designed or used to convey technology competitiveness must consider these complexities, but existing metrics often fall short. For example, the levelized cost of energy does not consider the system economic value of the various technologies nor does it consider services beyond electricity production. Various other metrics have been designed with the purpose of more-accurately communicating the economic viability of electric system technologies. In this report, we summarize the primary sources and components of costs and value and review the known competitiveness metrics by presenting their definitions, applications, advantages, and disadvantages. We also introduce a new set of competitiveness metrics, which we refer to as System Profitability metrics, that more-directly applies the economic principles of return-on-investment to electric system technologies. We use conceptual examples to show how the System Profitability metrics better reflect economic viability and relative technology competitiveness compared with existing metrics. We also describe how competitiveness metrics can be quantified using optimization-based models and demonstrate this capability using a U.S. electric sector capacity expansion model.
Deposit high purity Alumnium on Nb in support of conduction cooled SRF cavities
The project will demonstrate a potential manufacturing method that could result in a means to operate superconducting radio frequency (SRF) cavities without liquid cryogens. The technical approach sought to apply high-purity (99.999%) aluminum to cavity-grade niobium components via a new and proprietary electron-beam additive manufacturing technique contributed by PAVAC. High thermal conductivity of the aluminum could enable a cryocooler, which is a compact electrically powered refrigeration device, to extract sufficient heat for operating the cavity for a variety of applications. Trial coatings of niobium components were to be evaluated for metallurgy, mechanical bonding, and thermal and electrical conductivity using superconducting materials characterization facilities at Fermilab. The results of the characterization were intended to provide process feedback and optimization to PAVAC. During the project, PAVAC completed one set of samples. However, due to a business reorganization, PAVAC choose not to proceed toward a second set of samples using their proprietary approach. The PAVAC technical goal was replaced by a Fermilab goal to determine whether high-purity aluminum could be attached to niobium by a system of welded stud anchors and fasteners. The project pivoted to evaluations of trial stud welded anchors using infrastructure and expertise similar to that applied to the PAVAC applied coatings.
Next-Generation Electric Motors and Electromagnetic Devices (CRADA Final Report)
As part of the Cyclotron Road program, the Foli Research team investigated electric motors and other electromagnetic devices additively manufactured by depositing fine conducting wire onto a substrate. By leveraging modern motion control and efficient upstream manufacturing processes, the team explored using geometric control and turnkey production comparable to printed circuit board manufacturing, aiming at ten-fold improvements in signal density, while eliminating the material use, cost, and complexity overheads of subtractive processes at large scales. Owing to the achievable density and additive scaling, disparate components became monolithic, and disparate processes were combined with the aim of reducing development costs, uncertainties, and timelines. When applied to electric motors, this technology may enable agile manufacturing of next-generation designs, with dramatic increases in achievable power density and material utilization. Electric motors represent the single largest user of electricity in the U.S. and a critical component of decarbonized infrastructure. Despite this significance, the manufacturing of motors and other electromagnetic devices remains capital-intensive, labor-intensive, and performance-limiting. Advanced manufacturing processes were required to produce high-performance, low-cost, application-specific electric motors and electromagnetic devices to support an electrified future.