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DOE OSTI2025

Build-To-Replace Strategy to Reduce O&M Costs of Advanced Reactors

This paper targets the goal of reducing fixed operations and maintenance (O&M) costs to $2/MWh for advanced reactor (AR) designs, an order of magnitude reduction from current nuclear fleets. Such goal will be severely constrained if the underlying assumptions of O&M approaches and practices are not questioned and reexamined, especially today when changes can be implemented effectively and efficiently. Achieving a 90% reduction in AR O&M costs requires a completely new way of thinking – a paradigm shift – not through incremental, technology-focused approaches alone. Here, we address this challenge by evaluating the impact of moving to shorter design life for major structures, systems and components (SSCs) and shorter, more predictable refurbishment cycles as modeled by the commercial airline industry. This paper provides a brief overview of this different mindset to O&M applied to ARs: the build-to-replace approach. We provide a direct example of analysis of a build-to-replace scenario by identifying and evaluating scenarios for reduced system and component lifetimes and associated replacement and refurbishment schedules to evaluate impacts on O&M costs and other lifecycle elements such as SSC reliability.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Ensuring Safe, Effective, and Reliable Use of Artificial Intelligence-Based Applications for Nuclear Electricity Generation through a Systems Approach

There is a significant potential to reduce operating and maintenance cost at nuclear power plants using artificial intelligence (AI) and machine learning (ML). For instance, AI/ML has the potential to significant improve work management processes, condition reporting, and plant surveillance activities. However, the nuclear industry has been slow in adopting AI/ML due to several multifaceted barriers discussed in this paper. This work presents such multidisciplinary approach intended to 1) accelerate industry adoption of AI/ML-based applications at nuclear power plants and 2) ensure their safe, reliable, and effective use. This approach is discussed further in this work and will be used to address overarching challenges associated with AI deployment at scale to provide industry guidance that support accelerated adoption of AI/ML technologies throughout the industry.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Artificial Intelligence and Digital Engineering as Enablers for System Engineering in the Energy Sector

Systems engineering is of utmost importance for the success of high-cost, high-complexity megaprojects, which are common in the energy sector. However, the traditional document-centric systems engineering approach tends to be labor-intensive and time-consuming, which has inhibited its full adoption despite proven metrics on its return on investment. However, with the modern approach of digital engineering and technological advancements in artificial intelligence (AI) technologies, the barriers to systems engineering adoption can finally be broken. This paper goes through the systems engineering V-model for lifecycle management and assesses the current state of implementation of digital engineering (especially, mod-el-based systems engineering, digital twins, and digital threads) and AI for each step. It was observed that a combination of digital engineering and AI is being used across different industries to accelerate and optimize systems engineering processes such as concept development, requirements management, architecture definition, system development, verification and validation, operations, and maintenance. Specifically in the energy sector, AI-augmented digital engineering has shown initial potential in accelerated development and deployment, performance optimization, anomaly detection, predictive maintenance, and configuration management. However, challenges remain in integrating DE and AI into an end-to-end system lifecycle management ecosystem safely and reliably. Addressing these challenges and continuously developing impactful tools will enable fast, efficient, and high-frequency deployment of power generation capabilities to keep up with the world’s energy demands and build energy security.

42 - ENGINEERING↗

DOE OSTI2025

Artificial Intelligence and Digital Engineering as Enablers for Systems Engineering in the Energy Sector

42 - ENGINEERING↗

DOE OSTI2020

The Corrective Maintenance Paradigm Shift at Hanford's Tank Farms - 20077

Hanford's Tank Farms facilities have been used to safely store waste for over 70 years, with the first single-shell tanks being constructed in 1943. Tank Farm facilities consist of 149 single-shell tanks, 28 double-shell tanks, an evaporator facility, and wastewater treatment facilities. Tank Farm facilities are aging, with a tremendous corrective maintenance burden on the Tank Farm contractor. The mission of Tank Farm facilities is soon changing from waste storage to waste staging for the Hanford Waste Treatment and Immobilization Plant (WTP). WTP operations will demand a significant increase in Tank Farm facility operations, in which corrective maintenance outage windows will shrink drastically. This realization has forced the Tank Farm contractor to consider a paradigm shift in Tank Farm facilities Maintenance planning, and the use of reliability Engineering tools. The Tank Farm Production Operations Engineering Cognizant System Engineering (CSE) organization has led the way in motivating this paradigm shift. This shift has been realized through the use of: 1) technical exchange with other Department of Energy (DOE) contractors to develop improvements in the CSE program, 2) a shift from the use of lagging to leading system health indicators, and 3) a Plant Health Committee to unite Engineering, Operations, and Maintenance personnel toward a productive maintenance strategy. The CSE organization has held several technical exchanges with other DOE contractors to discuss CSE concepts, and how to better maintain aging infrastructure. The technical exchange with other contractors has greatly reduced the time required to make improvements in the Tank Farm CSE program. Other DOE contractors have already faced issues surrounding aging infrastructure, and have vast experience in improving the reliability and usable life of structures and components in nuclear facilities. The past CSE program used lagging health indicators to determine the health of systems. The key lagging indicator used to determine system health was availability, which is the percentage of time that a facility was ready for operation compared to the time the facility was demanded for operation. Availability was a good indicator of health in the waste storage mission of Tank Farms, where safe storage was the most important function of the facility, and where maintenance outage windows were typically long-duration. In current and future operations, outage windows are reducing, resulting in the need for much more reliable systems. Systems that have had high availability may suddenly become inoperable due to a failed component or sub-system. In several instances, the use of availability as an indicator of system health failed to predict system/equipment failure before its occurrence. In discussions with other DOE contractors, a set of reliability tools, including leading indicators of health, has been implemented in the CSE program. This primarily involves the use of failure modes and effects analysis and the study of equipment failure to develop system monitoring plans that focus on trending data to detect oncoming equipment failure ahead of time. In addition, the use of a Plant Health Committee has added significantly to the paradigm shift from a corrective maintenance philosophy to the use of predictive and preventive maintenance. The Plant Health Committee is a chartered team consisting of Engineering, Operations, and Maintenance personnel. CSEs use this forum to present the results of their performance monitoring, including the presentation of health via leading health indicators. The most positive aspect of this committee is the communication that it creates within these critical organizations. The Operations and Maintenance organization benefit from focusing maintenance on the reliability-centered focus provided by Engineering. Engineering benefits from the operational experience of the Operations organization and from the failure data that can be provided by Maintenance personnel. The continued use of the Plant Health Committee is expected to further decrease maintenance outage times, in better support of oncoming 24/7 operations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Language-Theoretic Data Analysis to Support ICS Protocol Baselining

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Masking of photovoltaic system performance problems by inverter clipping and other design and operational practices

We describe how performance problems can be “masked,” or not readily evident by several causes: by photovoltaic (PV) system configuration (such as the size of the PV array capacity relative to the size of the inverter and the resultant clipped operating mode); by instrumentation design, installation, and maintenance (such as a misaligned or dirty pyranometer); by contract clauses (when operational availability is transformed to contractual availability, which excludes many factors); and by identified management and operational practices (such as reporting on a portfolio of plants rather than individually). A simple method based on a duration curve is introduced to overcome shortcomings of Performance Ratio based on nameplate capacity and Performance Index based on hourly simulation when quantifying masking effects, and inverter clipping and pyranometer soiling are presented as two examples of the new method. With a better understanding of the non-transparency of masking issues, stakeholders can better interpret performance data and deliver improved AC and DC plant conditions through PV system operation and maintenance (O&M) for improved performance, reduced O&M costs, and a more consistently delivered, and reduced, levelized cost of energy (LCOE).

14 SOLAR ENERGY↗

DOE OSTI2020

Markov Process to Evaluate the Value Proposition of a Risk-Informed Predictive Maintenance Strategy

To achieve high-capacity factors, the nuclear fleet has relied on labor-intensive and time-consuming operation and preventive maintenance programs for plant systems. Manually performed inspection, calibration, testing, and maintenance of plant assets at periodic frequencies, along with time-based replacement of assets irrespective of condition, have resulted in a costly, labor-centric business model. Fortunately, there are technologies that can eliminate unnecessary preventive maintenance activities by deploying risk-informed predictive maintenance, enabling the transition to a technology-centric business model. The technology-centric business model will enable plants to optimize and automate maintenance activities, leading to cost reductions since labor is a rising cost and technology is a declining cost. The implementation of scalable technologies and methodologies across plant systems and across the nuclear fleet is critical for successful deployment of a risk-informed predictive maintenance strategy at commercial nuclear power plants. The work presented in the report is being developed as part of a collaborative research effort between Idaho National Laboratory and Public Service Enterprise Group Nuclear, LLC. This report describes the technical basis using the Markov Process to evaluate the value proposition for the risk-informed predictive maintenance strategy for the circulating water system. The plant process data from the Salem nuclear plant’s circulating water system is utilized to develop a Markov chain risk models and formulation to estimate the loss and gain in revenue based on plant availability. The outcomes presented in this report provides the technical basis for extensive quantitative evaluation of a scalable risk-informed predictive maintenance strategy as part of future research.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Dispatch optimization of electric thermal energy storage within System Advisor Model

A stand-alone electric thermal energy storage (ETES) system converts low-value electricity into heat using resistance heating elements. During periods of high-value electricity, an ETES system uses a thermodynamic power cycle to convert stored thermal energy back to electricity. These dispatchable systems derive value from their ability to store energy when prices are low and generate electricity when prices are favorable, i.e., energy arbitrage. Consequently, dispatch optimization of system operations, through maximizing revenue subject to system constraints, is essential to evaluate the economic value of a particular system design. While stand-alone ETES systems offer potential advantages as dispatchable grid storage technologies, there is a lack of a neutral third-party, publicly available, open-source model to evaluate the performance, dispatch, and financial viability of these systems. To address this problem, we have developed a techno-economic model for stand-alone ETES systems, within National Renewable Energy Laboratory's (NREL's) System Advisor Model (SAM). We implement a mixed-integer linear program to determine an ETES optimal operating schedule that maximizes electricity sales less maintenance costs caused by operation and cycling given temporal-varying grid electricity prices. Our contributions include a mixed-integer linear program for energy arbitrage of an ETES system, an ETES performance model through a publicly-available software (i.e., SAM), and an exercise of our model through case studies that compare ETES operational strategies and annual financial metrics. With our dispatch optimization model, we were able to improve revenue by 20% compared to a myopic heuristic while reducing the operational cost of the ETES system through decreases in cycle starts, cycles per day, and heater starts.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Panel Session 2: Hot Topics in US DOE Environmental Management

The well-attended Panel Session was chaired by Martin Schneider. The four panelists did not provide presentations. Rather the session was a discussion focusing on pressing issues facing US DOE Environmental Management (EM) sites and how the program is moving forward. The session began by momentarily reflecting on a success: the three Tank Waste Treatment Facilities will soon be coming online. These three facilities will treat as much waste in two years as was treated in the past 30 years. That is a significant milestone in progress. Also, safety enhancements at WIPP are a big success. The panelists noted that there will be challenges with the victories of the startup of the Waste Treatment Facilities. Treating tank waste is the last EM mission and will help with the relationships with the stakeholders, regulators and Congress. One of the biggest challenges will be moving back to full operation mode. Although the operation will increase productivity of reducing/managing the tank waste, it will decrease life cycle cost and lessen years of cleanup. The challenge will be having people understand that EM will be operating 24/7 and that maintenance will be key in keeping the operations. EM will be working together with the regulators to show tangible progress that will be effective and efficient. By working together, they can find opportunities/technologies for streamlining and accelerating cleanup. Recent changes to the regulatory framework between DOE-EM Los Alamos Field Office and New Mexico Environmental Department have helped cleanup in Los Alamos. Every year EM and the agencies review progress and come to agreements on the next work priorities. At Savannah River Site, the Federal Facility Agreement among EM, South Carolina Department of Health and Environmental Control, and Environmental Protection Agency (EPA) has developed a small core team that work are shared by together in resolving issues that come up. The discussion moved on to how progress can be made by sharing lessons learned among the contractors. An example of how these learned lessons can be shared is that key representatives from projects across the EM sites participate in various forums to review/contribute to the work planned. Other opportunities can be by temporary assignments of DOE staff to gain experience and by monthly EM Headquarters report that provide the lessons learned across the EM sites. The panelists discussed how skyline changes are the best examples of tangible progress. Decontamination and Demolition (D and D) of structures are the easiest tangible progress that can be seen. Whereas tank waste cleanup is the hardest to see. Disposal of waste onsite versus offsite is another challenge, and timely discussions are necessary to get to the best value to the government.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Enhancing PV Inverter Reliability Through Predictive Maintenance: Insights from Retrofitting of PV Inverters

Photovoltaic (PV) systems represent a cornerstone in the global shift toward sustainable energy generation, with inverters serving as the crucial link between solar panels and the grid. Despite their pivotal role, inverters are susceptible to failures, contributing significantly to maintenance events and operational disruptions in large-scale PV plants. This white paper investigates the importance and methodologies of predictive maintenance strategies that monitor the component-level pre-failure signatures on PV inverters. Through a comprehensive survey of literature and industry professionals, insights on preventive maintenance and retrofitting practices have been gathered. The expert elicitation helps shed light on common challenges and opportunities for improving PV system reliability, particularly inverter reliability. By addressing these challenges, the white paper aims to enhance the long-term viability and effectiveness of solar PV plants in the renewable energy landscape, contributing to the global transition toward environmentally friendly energy generation.

14 SOLAR ENERGY↗

DOE OSTI2023

A Hybrid Reliability Model Using Generalized Renewal Processes for Predictive Maintenance in Nuclear Power Plant Circulating Water Systems

Not Available

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Lessons Learned From Ventilation and Glovebox Flooding Via Overfilling of the Wet Vacuum System in a Plutonium Facility

In the summer of 2021, operations personnel requested maintenance personnel to fill a wet vacuum (Wetvac) seal water tank in a plutonium facility at Los Alamos National Laboratory (LANL). After the filling was finished, the fill valve of the Wetvac seal water tank was left open and a ‘dead-man’ valve on an isolation line failed to close properly. After a series of other failures, the water exited the glovebox and contaminated three rooms of the first floor of the facility and an underlying area in the basement. A retrospective analysis of this event determined that there was no risk of a criticality due to the inherent design features of the ventilation system. This paper will explain the driving factors behind how this event was able to happen, as well as some of the major lessons learned that can be universally applied to other nuclear facilities. One of the main causes of the event was the delegation of work to maintenance personnel that were not qualified for the work being asked of them. Additionally, there was a lack of coordination between criticality safety engineers and facility operations equipment owners regarding equipment and connections present on the seal water tanks for the Wetvac, specifically the presence of overflow drain lines. The respective criticality safety evaluation credited an overflow drain line being present on the seal water tanks that was later found to have not been present. Lastly, there are lessons to be learned regarding equipment configuration and designing systems with safety in mind.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Model-Based Investigation of Multi-Fault Interactions and Performance Degradation in Residential Heat Pump Systems

Faults in heat pump systems can significantly degrade performance, reduce efficiency, and accelerate component wear, leading to higher operating costs and maintenance demands. While numerous studies have investigated the impact of individual faults, the interactions between multiple concurrent faults remain insufficiently understood, despite their common occurrence in real-world operation. This study conducts a comprehensive simulation analysis of multiple simultaneous faults in a vapor compression heat pump using a validated heat pump design model (HPDM) tool. Detailed component-level modeling methods are implemented to examine performance sensitivity under combinations of refrigerant flow and heat exchanger faults. The results reveal complex fault interactions that can mask or amplify system deviations, challenging conventional diagnostic approaches. Findings from this work provide meaningful insights for the development of more robust fault detection and diagnosis algorithms, supporting improved reliability and energy efficiency in next-generation heat pump technologies.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

DOE OSTI2020

Integrating Commercial Ready Autonomous Robotic Platforms to Enhance Worker Safety and Efficiency - 20053

This paper will explore the challenges and triumphs of implementing advanced robotic systems and the supporting technology for the waste management industry. Deployment-ready solutions for autonomous robotic platforms are new to the radioactive waste management industry and have been slow to implement across the complex. Specifically, it will explore Hanford Tank Operations Contractor's implementation of ground-based autonomous robotic platforms to enhance workforce safety and efficiency. The first objective of the project is to demonstrate safe operation of autonomous instrumented robots, followed by a scaling up of capabilities for the platform to meet any additional requests of internal stakeholders. Autonomous robotics platforms offer a fantastic range of capabilities that will aid in decreasing long-term liability of radioactive waste management industry by enhancing clean-up efforts and worker safety. Over the past five years, deployment-ready solutions for autonomous robotic platforms have come a long way. Autonomous robotic platforms are increasingly available to purchase from many vendors, often for prices under $100,000. Additionally, the vendors who produce these products are efficient in accommodating customized solutions to unique challenges, such as those often found in the radioactive waste management industry. However, the newness of this technology to the radioactive waste management industry and has resulted in a slow implementation across the complex. This paper will explore the challenges and triumphs of implementing advanced robotic systems and supporting technology for the waste management industry. Specifically, it will explore Hanford Tank Operations Contractor's implementation of ground based autonomous robotic platforms to enhance workforce safety and efficiency. While the company has utilized robots in many parts of the tank farms mission, this was first attempted in the deployment of an autonomous platform that required no operator with only minor maintenance and created challenges not yet encountered. These challenges included stakeholder buy-in, operational safety, procurement uncertainties, adaption of 'off the shelf products, overcoming the 'Fukushima complexity' perception, security concerns, and the initial criteria down select. Hanford Tank Operations Contractor's management identified the need for a workforce protecting low cost robotics solution in the fall of 2017. The project scope generated was part of the response to the Tank Vapor Assessment Team recommendation to enhance the safety of the workforce by utilizing new technology. Since the projects inception, it has been incorporated into the Tank Stewardship Plan. This project was unique to Hanford Tank Operations Contractor, as the company does not frequently incorporate advanced technology for field deployment quickly. The project was also progressive to the Hanford Tank Operations Contractor as it functions as a partnership project with a local university. The first objective of the project is to demonstrate safe operations of autonomous instrumented robotics, monitoring and collecting data, and the wireless transmission of data to a central computing system. Following the completion of this first objective, the project will scale up capabilities of the platform to meet the requests of additional internal stakeholders throughout the tank farms - including completion of specific in-field tasks. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Are System Baselines within OT Environments Feasible?

Critical infrastructure stakeholders need to baseline their systems to understand expected protocol communications.Baseline behaviors may vary based on operational context.Expected operations during a maintenance window, for example, may be different from normal operations.Furthermore, constructing system baselines for Industrial Control Systems (ICS) is difficult and time-consuming.ICS processes generate artifacts expressed across heterogeneous data sources such as network and device logs. There needs to be a corpus of data in order to develop and compare methods that evaluate the feasibility, performance, and generality of approaches to construct baselines for ICS events. Standalone repositories of network packet captures are insufficient to develop methods to classify or recognize operational events expressed across multiple data sources. Moreover, static data corpora do not enable researchers to compare the impact of changing the underlying system for which a baseline is being constructed and this limits the ability to evaluate the performance of system baselines given system changes (e.g. patches, configuration, maintenance events). In order to address these limitations within the community, this talk intends to promote discussion about the state of the practice of constructing baselines. In this manner, we can continue to understand requirements within industry that are not being met by current approaches to baseline construction. This talk builds on two previous talks on the topic of system baselines for OT environments. First, Weaver co-presented at the RSA Conference ICS Sandbox with Dan Gunter. The talk confirmed the need within industry to construct baselines across multiple types of data sources relative to the semantics of specific business processes. Second, Weaver presented at IEEE Security and Privacy Workshop on Language-Theoretic Security.

02 PETROLEUM↗

DOE OSTI2020

Retail Hydrogen Station Reliability Status and Advances

One of the most vital emerging commercial markets for hydrogen is fuel cell-powered mobility including cars, trucks, and buses. These vehicles are refueled via a network of hydrogen fueling stations, with the highest number of U.S. stations being in California. The numbers of both fuel cell electric vehicles (FCEVs) and hydrogen stations have increased in the last two years, with anecdotal information from FCEV drivers indicating that station reliability is hurting the consumer acceptability of FCEV technologies. Therefore, this study benchmarks the current state of hydrogen station reliability in practice and presents on-going research that is investigating the failures that are contribute to hydrogen station reliability issues. This is accomplished with an analysis of operation, safety, and maintenance data from hydrogen stations and fuel cell electric vehicles to benchmark the maintenance and failure of hydrogen stations and their components. This analysis, of over 5,000 station maintenance events, presents the leading maintenance categories and failure rates, and is a prerequisite to the development of data-driven reliability improvement plans. We present a reliability growth analysis and on-going research into the root causes of failure for dispensers, a particularly failure-prone subsystem.

08 HYDROGEN↗

DOE OSTI2021

Industry Level Integrated Fire Modeling Using Fire Risk Investigation in 3D (FRI3D)

The software Fire Risk Investigation in 3D (FRI3D) has been developed over the last 2 years to integrate 3D spatial modeling with existing fire probabilistic risk assessment (PRA) models and fire simulation codes. The goal of this research and development is to automate many of the fire analysis manual tasks to reduce industry efforts in the initial fire modeling and operational costs for the model maintenance and evaluations required during normal plant operations. The tasks for Fiscal Year (FY) 2021 include first testing the FRI3D modeling capabilities by importing an industry fire model into FRI3D and making a 3D model of a complex/high-risk significant area. (For this work, the switchgear room was chosen.) Then, the second task of FY 2021 is to develop a dynamic fire PRA process that can help optimize traditional fire PRA models. The switchgear room model will be used for the dynamic fire PRA work. This report describes the work and insights learned when using FRI3D software to model both a Nuclear Regulatory Report (NUREG) example models and a full industry switchgear room.

97 MATHEMATICS AND COMPUTING↗