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DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

In recent years, there has been considerable effort to modernize existing and new nuclear power plants with digital instrumentation and control systems (DI&C). However, there has also been considerable concern both by industry and regulatory bodies for the risk and consequence analysis of these systems. Of particular concern are digital common cause failures (CCFs) specifically related to software defects. These “misbehaviors” by the software can occur in both the control and monitoring of a system. While many new methods have been proposed to identify potential software failure modes, such as Systems-theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), etc., these methods are focused primarily on the control action pathway of a system. In contrast, the information feedback pathway lacks unsafe control actions (UCAs), which are typically related to software basic events; thus, assessment of software basic events in such systems is unclear. In this work, we present the idea of intermediate processors and unsafe information flow (UIF) to help safety analysts trace failure mechanisms in the feedback pathway and how they can be integrated into a fault tree for improved assessment capability. The concepts presented are demonstrated in two comprehensive case studies, a smart sensor integrated platform for unmanned autonomous vehicles and another on a representative advanced human system interface (HSI) for safety critical plant monitoring. The qualitative software basic events are identified, and a fault tree analysis is conducted based on a modified Redundancy-guided Systems-theoretic Hazard Analysis (RESHA) methodology. The case studies demonstrate the use of UIF and intermediate processors in the fault tree to improve traceability of software failures in highly complex digital instrumentation feedback. The improved method can also clarify fault tree construction when multiple component dependencies are present in the system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Distributed Wind Monitoring Best Practices

Accessible performance and operational data have been identified as a key enabler for distributed wind energy industry advancement. While utility-scale wind turbines benefit from reliable and continuous supervisory control and data acquisition (SCADA)-based monitoring platforms, monitoring of the U.S. fleet of distributed wind (DW) turbines has been more inconsistent, unreliable, and sometime difficult to access. Without fleet monitoring data, the industry will never understand and thus work to improve turbine under-performance and reliability issues. For the DW industry to scale up, attract investors, and boost credibility, fleetwide monitoring must be robust and reliable, select data must be made accessible to stakeholders, and the data must be in a format useful to users. To help move the industry toward a more standardized, accessible stream of monitoring data, this distributed wind monitoring best practices report attempts to cover topics including key monitoring channels, hardware, communication strategies, and accessibility. Strategic engagement with DW original equipment manufacturers (OEMs), service providers, lab and university researchers, testing organization, certification bodies, end users and solar photovoltaic (PV) monitoring experts has enabled a better understanding of the current state-of-the-art of monitoring and aided in articulating this set of best practices that will guide OEMs toward harmonized monitoring strategies, aimed at a future goal of achieving accessible performance and operational data for the entire fleet of U.S. distributed wind turbines.

17 WIND ENERGY↗

DOE OSTI2026

Attention-based 3D – convolutional neural network model for mechanical property predictions using visible light images in metal additive manufacturing

Additive manufacturing (AM), while commonly used for rapid prototyping and creating components with complex geometries, has not been widely adopted for critical applications across the aerospace, automotive, defense, energy, and medical industries. This is, in part, due to the challenges of controlling flaws and uncertainty in the mechanical behavior of additively manufactured components. In recent years, there has been an increase in research aimed at predicting the final mechanical properties of additively manufactured components during the printing process. To address these issues, a 3D-CNN model was trained using low-cost in situ visible-light camera data, anomaly classifications, and the chosen process parameters to predict the ultimate tensile strength (UTS), yield strength (YS), total elongation (TE), and uniform elongation (UE). The 3D-CNN layers of the model employed attention mechanisms to prioritize features in the data, thereby improving prediction accuracy. Furthermore, the effect of each process parameter and anomaly class is investigated using attention-based dynamic sigmoid weighted gates to interpret the influence each class has on the final prediction. Different combinations of the in situ data were fed into the 3D-CNN, with varying amounts of image layers, to determine the ideal combination for predicting mechanical properties in situ. Here, the 3D-CNN model achieved mean absolute percentage errors (MAPE) below 5% for both UTS and YS while using only a single camera input and under half of the available image layers.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Ensemble voting-based fault classification and location identification for a distribution system with microgrids using smart meter measurements

This study presents an ensemble learning approach for fault classification and location identification in a smart distribution network containing photovoltaics (PV)-based microgrid. Lack of available data points and the unbalanced nature of the distribution system make fault handling a challenging task for utilities. The proposed method uses event-driven voltage data from smart meters to classify and locate faults. The ensemble voting classifier is composed of three base learners; random forest, k-nearest neighbours, and artificial neural network. The fault location (FL) task has been formulated as a classification problem where the fault type is classified in the first step and based on the fault type, the faulty bus is identified. The method is tested on IEEE-123 bus system modified with added PV-based microgrid along with dynamic loading conditions and varying fault resistances from 0 to 20 Ω for both unbalanced and balanced fault types. A further sensitivity analysis has been done to test the robustness of the proposed method under various noise levels and data loss errors in the smart meter measurements. The ensemble method shows improved performance and robustness compared to some previously proposed FL methods. Finally, the proposed method has been experimentally validated on a real-time simulation-based testbed using a state-of-the-art digital real-time simulator, industry standard DNP3 communication protocol and a cpu-based control centre running the FL algorithm.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Study of synchronous RF pulsing in dual frequency capacitively coupled plasma

Low-pressure multi-frequency capacitively coupled plasmas (CCPs) are used for numerous etch and deposition applications in the semiconductor industry. Pulsing of the radio-frequency (RF) sources enables control of neutral and charged species in the plasma on a millisecond timescale. The synchronous (i.e. simultaneous, in-phase) pulsing of both power sources in a dual frequency CCP is examined in this article. Due to the low gas pressure, modeling has been done using the electrostatic particle-in-cell/Monte Carlo collision method. Here, the objective of this work is to investigate the sensitivity of the plasma properties to small changes in timing during synchronous pulsing of the two RF sources. It is demonstrated that small deviations in the on and off times of the two RF sources can lead to major changes in the plasma characteristics. This high sensitivity is of concern for process repeatability but can be utilized to enable better control of the dynamics of plasma-surface interaction. In the simulations, the pulsing parameters (on and off times and ramp rates) are varied and the temporal evolution of plasma characteristics such as electron density (n e ), species current at the electrode, and electron temperature are examined. It is demonstrated that if the low-frequency (LF) source is turned off a few μs before (or after) the high-frequency source, n e during the off-state is significantly higher (or lower) due to the frequency coupling effect. Similarly, turning on the LF source with a small delay results in a sharp increase in the plasma density when the RF sources are turned on.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Grid Integration of Offshore Wind Power: Standards, Control, Power Quality and Transmission

Offshore wind is expected to be a major player in the global efforts toward decarbonization, leading to exceptional changes in modern power systems. Understanding the impacts and capabilities of the relatively new and uniquely positioned assets in grids with high integration levels of inverter-based resources, however, is lacking, raising concerns about grid reliability, stability, power quality, and resilience, with the absence of updated grid codes to guide the massive deployment of offshore wind. To help fill the gap, this paper presents an overview of the state-of-the-art technologies of offshore wind power grid integration. First, the paper investigates the most current grid requirements for wind power plant integration, based on a harmonized European Network of Transmission System Operators (ENTSO-E) framework and notable international standards, and it illuminates future directions. The paper discusses the wind turbine and wind power plant control strategies, and new control approaches, such as grid-forming control, are presented in detail. The paper reviews recent research on the ancillary services that offshore wind power plants can potentially provide, which, when harmonized, will not only comply with regulations but also improve the value of the asset. The paper explores topics of wind power plant harmonics, reviewing the latest standards in detail and outlining mitigation methods. The paper also presents stability analysis methods for wind power plants, with discussions centered on validity and computational efficiency. Finally, the paper discusses wind power plant transmission solutions, with a focus on high-voltage direct-current topologies and controls.

17 WIND ENERGY↗

DOE OSTI2022

Spectroscopic Investigation of Catalyst Inks and Thin Films Toward the Development of Ionomer Quality Control

As the production of polymer electrolyte fuel cells expands, novel quality control methods must be invented or adapted in order to support expected rates of production. Ensuring the quality of deposited catalyst layers is an essential step in the fuel cell manufacturing process, as the efficiency of a fuel cell is reliant on the catalyst layer being uniform at both the target platinum loading and the target ionomer content. Implementing a quality control method that is sensitive to these aspects is imperative, as wasting precious metals and other catalyst materials is expensive, and represents a potential barrier to entry into the field for manufacturers experimenting with novel deposition processes. In this work, we analyzed catalyst inks to determine if their ionomer content could be quantized spectroscopically. Attenuated total reflection (ATR) Fourier transform infrared spectroscopic technique was investigated producing a signal proportional to the ionomer content. ATR spectroscopy was able to quantitatively differentiate samples in which the ionomer to carbon mass ratio (I/C) varied between 0.9 and 3.0. The I/C ratio was correlated to the measured ATR signal near the CF 2 vibrational bands located between 1100 cm −1 and 1400 cm −1 . The experimental results obtained constitute a step toward the development of novel quality control methodologies for catalyst inks utilized by the fuel cell industry.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

CYVET: A Cyber-Physical Assurance Framework Based on a Semi-Supervised Vetting Approach

The project is designed to directly address the needs described in the Topic Area 4 (“Cybersecurity Verification and Validation”) of the CEDS’19 Research Call. The proposed CYVET system directly addresses the need to elevate the current industry capabilities to verify and validate OT cybersecurity and associated control system infrastructure. Currently, there is a significant gap in the energy sector’s capability in that regard during infrastructure improvement, equipment procurement, and compliance certification. CYVET provides that needed capability. CYVET is device and architecture agnostic and thus broadly applicable across the energy sector. The goal of this project is to develop and deliver a cybersecurity verification and validation framework testing capability to verify and validate OT equipment, software, and the underlying control system architecture. The primary project objectives are (i) Verification: the synthesis and reconciliation of standards and vendor supplied features, (ii) Validation: the generation, execution, and presentation of testing scripts of verified security features, and (3) Demonstration: apply the developed technology capabilities for verification and validation at a relevant end-user facility in the energy sector.

Lopez Jr, Juan↗

DOE OSTI2022

Flexible Plant Operation and Generation Technical Program Plan for FY2023

This report presents the Technical Program Plan for Fiscal Years 2023-2027 (FY2023 to FY2027) for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability Program—Flexible Plant Operation and Generation Research Pathway. The objective of this pathway is to carry out the research needed to help nuclear power plants diversify revenue generation for the life of these plants. The purpose of these research and development activities is two fold: (1) to reduce the technical and economic risks of implementing FPOG applications and (2) to provide guidance on relevant safety and environmental operating license reviews, amendments, and renewals. This pathway provides a clear understanding of the benefits of nuclear energy beyond electricity markets. A detailed description of the research and development activities that have been completed and that are planned for FY2023—FY2027 are presented in this report. These activities include completing the development of analysis tools to perform technical and economic assessments of realistic market opportunities for producing secondary energy products near nuclear power plants. They also include developing and demonstrating engineering systems and control concepts to dispatch thermal and electrical power to an industrial user. Additionally, this plan includes developing guidance for addressing potential regulatory and licensing requirements. In addition, the formation, purpose, and activities of a group referred to as the Hydrogen Regulatory Research and Review Group is discussed. An overview is also provided on the potential benefits of the Infrastructure Investment and Jobs Act (IIJA) Bill that will support the commencement of Regional Clean Hydrogen Hubs, and the Inflation Reduction Act (IRA) that provides compelling production tax credits for nuclear electricity and clean hydrogen using nuclear energy.

08 HYDROGEN↗

DOE OSTI2025

A Generic FSC Wind Park EMT Model with IEEE Std 2800-Compliant Fault Ride-Through Capability

The modern power grid is seeing more and more electricity come from renewable sources like wind farms, which use sophisticated power electronics instead of traditional spinning generators. To keep everything running smoothly and meet industry standards such as IEEE 2800, these systems need smart control strategies. In our work, we built a flexible computer model of a full-scale wind farm converter that can handle grid disturbances without shutting down. When a fault or storm hits, the model’s built-in logic automatically adjusts the currents it sends to the grid and protects its internal energy storage, ensuring the wind farm stays connected and doesn’t damage its own equipment. Once the disturbance clears, the model restores normal operation seamlessly, so there’s no long interruption in power delivery. At the same time, it carefully regulates the voltage where the wind farm ties into the larger grid, helping to maintain safe voltage levels across the network. Our simulations show that this control setup not only meets all the requirements of IEEE Standard 2800 but also allows the wind farm to recover quickly and predictably, keeping the lights on no matter what happens on the grid.

17 WIND ENERGY↗

DOE OSTI2023

Tanana River Test Site Model Verification Using the Marine and Hydrokinetic Toolkit (MHKiT)

The marine energy (ME) industry historically lacked a standardized data processing toolkit for common tasks such as data ingestion, quality control, and visualization. The marine and hydrokinetic toolkit (MHKiT) solved this issue by providing a public software deployment (open-source and free) toolkit for the ME industry to store and maintain commonly used functionality for wave, tidal, and river energy. This paper demonstrates an initial model verification study in MHKiT. Using Delft3D, a numerical model of the Tanana River Test Site (TRTS) at Nenana, Alaska was created. Field data from the site was collected using an Acoustic Doppler Current Profiler (ADCP) at the proposed Current Energy Converter (CEC) locations. MHKiT is used to process model simulations from Delft3D and compare them to the transect data from the ADCP measurements at TRTS. The ability to use a single tool to process simulation and field data demonstrates the ease at which the ME industry can obtain results and collaborate across specialties, reducing errors and increasing efficiency.

13 HYDRO ENERGY↗

DOE OSTI2023

Understanding the Uncertainty in the Technical Performance Level Assessment for Wave Energy

In recent years, the design and development of wave energy converters (WECs) has been explored with intense interest, with highly varying design concepts emerging globally across both research enterprises and industry. The design space for WECs is vast - many concepts ranging in functionality, control systems, power development systems, materials, and scale have been ideated and prototyped, but WEC technology has yet to converge. One critical element of the technology trajectory that governs the speed of adoption is the performance of a WEC concept. In analogous but more-established industries (such as aerospace, and environmentally sustainable electronics design), performance assessment is a quantitative method, based on historical data, that is used as an iterative tool to improve the design of these systems early on in the design process. Though more nascent than these approaches, in wave energy R&D, WEC performance has been assessed using the Technology Performance Level (TPL) assessment, which provides designers with a quantitative score, situating a grid-scale WEC concept on a scale from 1-9 (1 being the lowest performance, and 9 being the highest, trending with the oft-used Technology Readiness Level, or TRL). The TPL assessment is designed to be used during design iteration, when a WEC concept is fully ideated, to enable designers to consider potential means of improving the downstream performance of the concept. One concern that may be slowing the adoption of TPL among WEC developers is the inherent uncertainty in the assessment, and how uncertainty in the individual questions asked as part of the assessment may contribute to perceived inaccuracies in the final score. In this work, we explore the uncertainty present in the assessment and quantify this uncertainty using both traditional mathematical operations and a Monte Carlo simulation. Results imply areas of improvement of the TPL assessment, where reducing uncertainty will be most helpful to end users, enabling both TPL practitioners and users to understand with more accuracy those design elements that can be improved to impact device performance most substantively.

techno-economic analysis↗

DOE OSTI2024

Autonomous online optimization of a closed-circuit reverse osmosis system

As freshwater becomes increasingly scarce, many industrial and municipal water utilities look at premise-scale water treatment and reuse to meet water demand. Closed-circuit reverse osmosis (CCRO) has been proposed as a promising process design to do so. This sequencing batch process enables operation at higher brine salinity levels by means of a recycle flow. Optimal operation requires that the maximum salinity level at the membrane surface represents an optimal trade-off between brine disposal costs and energy efficiency. This maximum salinity level may change over time as the feed water composition changes and electricity markets fluctuate. In this article, we present the results of the experimental evaluation of an automatic technique for continuous online optimization, known as extremum seeking control. This technique has a long history in the process control community but has received little traction so far in the water industry. We modify this technique to enable its use for online optimization of CCRO, specifically to account for its sequential batch operation. We challenge the optimization schemes through several experimental tests and illustrate the advantages and drawbacks of extremum-seeking control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Model based co-simulation platform for integrated building system control and design optimization

Both steady-state and dynamic simulations have been widely used by HVAC&R industry to support product/equipment development for decades. Steady-state simulation focuses on the system mass, energy and momentum balance of an equilibrium state. It is based on high-fidelity components models, and thus is suitable for system and component design optimization. Dynamic simulation studies the system transient response and is generally used for controls development and verification. It usually does not require rigorous component models of high accuracy because 1) the commonly used PID control is feedback control whose control performance evaluation doesn’t require high fidelity system/plant model; 2) high-fidelity dynamic model significantly increases the number of equations and variables and creates tremendous challenge for math solver. For supervisory control, transactive control or optimization of an integrated building system, the HVAC&R equipment is often one of the sub-components to be controlled. High-fidelity equipment models are required for accurately evaluating control strategies. In addition, building equipment manufacturers have developed a lot of high-fidelity steady-state equipment/component models per their expertise. Thus, a platform that can integrate OEM high-fidelity steady-state model with dynamic building simulation and/or electric power system & grid simulation to support the development and verification of supervisory control for integrated building systems is necessary. In this study, ORNL’s heat pump design tool (HPDM) is utilized to develop a co-simulation platform for supervisory control and optimization in integrated building systems. It is based on a model that integrates high-fidelity steady-state simulation equipment models with dynamic building simulation. A practical case of using the proposed co-simulation platform to develop and evaluate the supervisory control and optimization is presented and discussed.

Sun, Jian↗

DOE OSTI2024

Pathways to commercial building plug and process load efficiency and control

Abstract To accomplish net-zero carbon emissions in the built environment by 2050, we must equitably decarbonize commercial buildings, including reducing plug and process loads (PPLs). PPLs are plug-in or hardwired electric and gas loads that are not associated with major building end uses like lighting and HVAC. Research shows PPL energy reduction strategies and control technologies have the potential to save energy. But even when implemented, these savings have rarely been achieved and there has not been widespread uptake in U.S. commercial buildings. We investigate why these technologies and strategies have not seen widespread adoption and identify behavior and technology pathways to increase PPL reduction in U.S. commercial buildings. We examined behaviors of commercial building stakeholders through 44 interviews and cross-referenced qualitative analysis findings with in-depth technical knowledge of existing PPL control technologies and reduction strategies. PPL control implementation must be paired with management strategies, such as occupant engagement and training, to achieve optimal savings, and best practices should be disseminated across the industry. We found that increasing access to cost and energy savings data will promote uptake of PPL control technologies and allow designers to better incorporate PPLs into building design. Improving access to funding for PPL energy efficiency projects and addressing the split-incentive problem will increase adoption of PPL efficiency and control. Code bodies should continue to include PPL monitoring and reduction measures in energy codes. Key building stakeholders, including cybersecurity and information technology teams, should be involved in PPL monitoring and reduction strategy processes for successful implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Implementation and test of an automated control hunting fault correction algorithm in a fault detection and diagnostics tool

Control hunting due to improper proportional–integral–derivative (PID) parameters in the building automation system (BAS) is one of the most common faults identified in commercial buildings. It can cause suboptimal performance and early failure of heating, ventilation, and air conditioning (HVAC) equipment. Commercial fault detection and diagnostics (FDD) software represents one of the fastest growing market segments in smart building technologies in the United States. Implementation of PID retuning procedures as an auto-correction algorithm and integration into FDD software has the potential to mitigate control hunting across a heterogeneous portfolio of buildings with different BAS in a scalable way. This paper presents the development, implementation, and field testing of an automated control hunting fault correction algorithm based on lambda tuning open-loop rules. The algorithm was developed in a commercial FDD software and successfully tested among nine variable air volume boxes in an office building in the United States. The paper shows the feasibility of using FDD tools to automatically correct control hunting faults, discusses scalability considerations, and proposes a path forward for the HVAC industry and academia to further improve this technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Grid Resiliency with a 100% Renewable Microgrid

San Diego Gas & Electric Company (SDG&E) installed America’s first and largest utility-scale microgrid in Borrego Springs in 2013. The first generation Borrego Springs Microgrid utilized diesel generators to form and stabilize the microgrid island, with support from grid-scale batteries and local solar photovoltaic (PV) generation. In this project, SDG&E in partnership with National Renewable Energy Laboratory (NREL) demonstrated through modeling, simulation and utility field testing that blackstart and islanding of the microgrid can be led with 100% renewable, inverter based resources (IBRs), to help reduce community reliance on conventional generation resources. Through equipment upgrades, grid-forming island leader capability was transitioned to a battery IBR instead of the Borrego Springs Microgrid diesel generators. A new microgrid controller was integrated to the microgrid and programmed to control and manage multiple energy storage systems. Synchrophasor and other power quality data verified autonomous, high-speed response of the IBRs through blackstart, islanding, and load step testing. Results of project field evaluations provide distribution systems operators (DSO) with increased confidence that renewable, IBR can replace traditional generators to blackstart and island microgrids and rapidly establish stable island frequency with rapid changes in peak power demand. Importantly, the project validated the integration feasibility of a distributed energy resource management system (DERMS) controller that manages multiple grid-forming and grid-following IBRs, establishing a standard design interface to reduce the complexity of integrating new DERs in the future and supporting replication by the industry. As a result of learnings in this project, SDG&E has implemented the microgrid controller strategy at multiple other microgrid sites, thereby validating the replicability of the solution. Hardware-in-the-loop (HIL) simulations including power and controller HIL hardware — along with electromagnetic transient (EMT) simulations of Borrego Springs Microgrid —informed adjustments to inverter parameters and were important to characterize the performance of the IBRs in relevant operating conditions before deployment. The EMT and HIL simulations of islanding the entire community are important contributions in providing confidence in IBR performance prior to future islanding of the community in the field. High-fidelity EMT and/or HIL simulation of IBRs can de-risk field operations, and its relevance and importance as a tool is increasing as distribution grids and microgrids become more complex and dynamic with an increasing proportion of renewable generation, distributed energy storage, and two-way power and energy flows.

24 POWER TRANSMISSION AND DISTRIBUTION↗