Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “time to failure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

BISON analyses of TRISO fuel performance, its dependence on time-at-temperature, and possible implications for fuel design and qualification

The Advanced Gas Reactor Fuel Development and Qualification (AGR) program has established a substantial technical foundation to support private entry into the U.S. high-temperature gas-cooled reactor market. However, emerging tristructural isotropic (TRISO)-fueled reactor applications include small modular reactors and microreactors with longer fuel residence times, which may expose fuels to higher time-at-temperature (TAT) values than were explored by the AGR program. Increased TAT could affect diffusive and thermomechanical behaviors such as Pd penetration, fission gas release, creep, and fission product transport. In this work, we applied multiscale best-estimate BISON fuel performance modeling to assess these effects within a representative design space based on the AGR-5/6/7 experiment and analyzed trends in predicted particle and compact fuel performance metrics with possible implications for near-term fuel design and qualification. BISON unambiguously predicted that TRISO fuel performance is sensitive to TAT. Increasing TAT was not predicted to increase the magnitude of failure-inducing tangential stresses in particle coating layers. Predictions obtained using a mechanistic model for Pd penetration indicated that penetration depth does not depend strongly on TAT. While these observations suggest that AGR testing provides a conservative upper bound for the steady-state operation of TRISO particles at lower powers and higher residence times, BISON also predicted that the release of poorly retained Ag would increase with TAT. Because these analyses applied models to extrapolate beyond the available experimental data, the authors recommend performing targeted experiments to confirm these predictions. Nevertheless, these predictions may provide reactor developers with enough confidence to make near-term design decisions associated with the potential fuel performance trade-offs of increasing TAT.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Predicting Future Laboratory Fault Friction Through Deep Learning Transformer Models

Machine learning models using seismic emissions as input can predict instantaneous fault characteristics such as displacement and friction in laboratory experiments, and slow slip in Earth. Here, we address whether the seismic/acoustic emission (AE) from laboratory experiments contains information about future frictional behavior. The approach uses a convolutional encoder-decoder containing a transformer model in the latent space, similar to models used for natural language processing. We test the model limits using progressively larger AE input time windows and progressively larger output friction time windows. The results demonstrate that very near-term friction predictions are indeed contained in the AE signal, and predictions are progressively worse farther into the future. The future predictions by the model of impending failure in the near-term are remarkably robust. This first effort predicting future fault frictional behavior with machine learning will aid in guiding efforts for applications in Earth.

58 GEOSCIENCES↗
DOE OSTI2022

Status Update on the Development of Transducers and Bonding Techniques for Enabling Acoustic Measurements of Damage in Microreactor Components

This report provides an overview of potential sensors and sensor-bonding techniques to enable the online acoustic interrogation of microreactor components and enhance structural health monitoring capabilities. The report focuses primarily on optical fiber–based acoustic sensors and describes initial experimental progress toward the deployment of these sensors for microreactor applications. The general approach is to monitor the resonant frequencies of microreactor components and search for evidence of structural defects that could indicate imminent failure. If properly identified, then the components could be repaired during the next reactor outage to prevent costly unplanned shutdowns. The ability to monitor the structural health of components could also reduce the need for time-consuming visual inspections and reduce staffing to improve microreactor economic viability. Increased sensor density is also one of the first steps to moving toward eventual semiautonomous operation. The expected microreactor conditions in which acoustic sensors must survive are characterized, including temperatures, neutron fluences, thermomechanical strains, and vibrational frequencies. Optical fiber–based acoustic sensors are identified as an attractive candidate for acoustic monitoring because of their high accuracy, immunity to electromagnetic interference, and resiliency in high-temperature, high-radiation environments. Optical fiber–based intrinsic sensors, such as type-II fiber-Bragg gratings and Fabry-Pérot Cavities (FPCs), are particularly attractive for a microreactor environment because of their high temperature stability, and FPCs also enable higher frequency interrogation with a lower sensitivity to radiation-induced drift. This report describes multiple interrogation systems, but the best interrogation system for a given situation will depend on the specific microreactor application, including the desired acoustic vibrational amplitudes, modes, and resonant frequencies. Initial experiments included fabricating three FPCs, tack-welding these FPCs to stainless-steel pipes or rods and performing room-temperature acoustic sensing tests to capture the vibrational frequency content. Peaks were identified in the measured frequency spectra and compared with the theoretical fundamental frequencies obtained from Euler-Bernoulli beam theory. Two of the three FPCs measured vibrational frequencies that generally matched those obtained from theory. Future work will include similar testing on pipes or other microreactor components with intentional flaws to evaluate the ability to determine changes in resonant frequencies. Finally, these tests will be repeated at high temperatures, potentially with an applied thermomechanical stress, to include environmental conditions similar to those for a microreactor application.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Deploying Software-Defined Networking in Operational Technology Environments

Software Defined Networking for Operational Technologies, referred to as OT-SDN, is a leading technology to secure critical infrastructure and command and control (C2) systems. As the name implies, OT-SDN networks are programmable, which allows system owners to utilize the characteristics of their physical process to inform the security of their network. There are best practices for deploying OT-SDN into an environment, whether it is all at once or over time (hybrid) that the network is converted to SDN technologies. Through the development of data mining tools and standardized process control, OT-SDN can be deployed reliably. These tools will minimize or eliminate any communication failures during the transition and provide the network owner with complete documentation of their environment. This documentation could enable or facilitate the network owner to pass any audits or policy checks (Authority to Operate) before being allowed to utilize the OT-SDN infrastructure.

Software Defined Networking, Operational Technolog↗
DOE OSTI2021

An Integrated High-performance Computing and Digital Real-time Simulation Testbed to Benchmark Closed-loop Load Shedding Algorithms in Power Systems

An integrated testbed using digital real-time simulator (DRTS) and a high-performance computing (HPC) cluster is presented here to compare speed and performance of computational schemes to mitigate time-critical issues in electric power systems. The first approach in this testbed validation is taken by running a set of closed-loop load shedding algorithms to compare and contrast two paradigms of arresting cascading failure propagation. Two algorithms involve solving DC and AC power flow model-based optimization problems to compute load shedding at different buses, while a model-based stochastic search using parallel computing provides a viable alternative. The algorithms are implemented in the DRTS-HPC testbed for the IEEE 14-bus benchmark transmission system. As a proof of the concept, simulation results are presented for implementation of closed-loop load-shedding algorithms for cascading failures in the DRTS-HPC testbed

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Hydropower Geotechnical Foundations: Current Practice and Innovation Opportunities for Low-Head Applications

Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to challenges frequently encountered with traditional approaches. With this understanding, it is critically important to understand and document the current state of practice for hydropower geotechnical foundations, identify key challenges, and define opportunities for innovative solutions. To this end, this report documents the current state of practice across the three main phases of geotechnical foundation development: (1) geotechnical site assessment, (2) design, and (3) construction for hydropower systems. It also describes the major challenges with conventional approaches and identifies opportunities for innovation to reduce hydropower foundations costs, timelines, and risks. Key takeaways from this report include the following: Approximately 80% of available low-head sites are expected to have foundations on soil beds rather than rock beds, suggesting that rockfill and earthfill dams may be the most cost-effective conventional dam type for new projects.; Geotechnical and geologic investigation activities are time-consuming and expensive but are essential to define the parameters and criteria needed for foundation design.; Certain riverbed soil and bedrock types present significant technical challenges or require expensive foundation construction, which can prove financially prohibitive for low-head project development.; Modular hydropower design and prefabricated modular foundations represent a promising but unproven paradigm for new hydropower development. Design and construction approaches using optimized and highly repeatable, reliable components would benefit project cost, time, and risk but require additional research and development.; Temporary construction features for foundations, including cofferdams, water diversion, and water control systems, can prove costly and have inherent construction risk.; For economically viable development, hydropower geotechnical foundations should be limited to 4 to 15% of the project’s total initial capital costs. Many proposed projects have experienced cost overruns attributable to foundation difficulties or surprises during construction. These overruns may have been due to inadequate investigations, lack of adequate engineering effort to tailor the structures to site geology and topography, and/or contractual terms, among other considerations.; Challenges for hydropower foundations and opportunities for innovative technology solutions are identified in the following areas (consistent with the three main phases of foundation development): Geotechnical site assessment, Foundation design and materials, Construction methods and technology. Ultimately, this report aims to provide information about geotechnical foundations for low-head hydropower and to motivate transformative technologies to support hydropower growth.

13 HYDRO ENERGY↗
DOE OSTI2024

Strain Field Around Individual Dislocations Controls Failure

Understanding material failure on a fundamental level is a key aspect in the design of robust structural materials, especially for metals and alloys capable to undergo plastic deformation. In the last decade, significant progress is made in quantifying the stresses associated with failure in both experiments and simulations. Nonetheless, the processes occurring on the most essential level of individual dislocations that govern semi-brittle and ductile fracture are still experimentally not accessible, limiting the failure prediction capabilities. Therefore, in the present work, a one-of-a-kind nanoscale fracture experiment is conducted on a single crystalline Cr bending beam in situ in the transmission electron microscope and for the first time quantify the transient strains around individual dislocations, as well as of the whole dislocation network during crack opening. The results reveal the importance of both pre-existing and newly emitted dislocations for crack-tip shielding via their intrinsic strain field and provide guidelines to design more damage tolerant materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

An integrated approach to understanding RF vacuum arcs

Although used in the design and costing of large projects such as linear colliders and fusion tokamaks, the theory of vacuum arcs and gradient limits is not well understood. Almost 120 years after the isolation of vacuum arcs, the exact mechanisms of the arcs and the damage they produce are still being debated. We describe our simple and general model of the vacuum arc that can incorporate all active mechanisms and aims to explain all relevant data. Our four stage model, is based on experiments done at 805 MHz with a variety of cavity geometries, magnetic fields, and experimental techniques as well as data from Atom Probe Tomography and failure analysis of microelectronics. The model considers the trigger, plasma formation, plasma evolution and surface damage phases of the RF arc. This paper also examines how known mechanisms can explain the observed sharp field dependence, fast breakdown times and observed surface damage. We update the model and discuss new features while also pointing out where new data would be useful in extending the model to a wider range of frequencies.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

The Natural and Accelerated Evolution of EVA Adhesion Through Intermediate Exposures

Ethylene vinyl acetate (EVA) encapsulants comprise the majority of the encapsulants currently in use; much work has been done to understand and model the adhesive characteristics of EVA-encapsulated modules, but limited work has provided reliable insight into adhesion during the intermediate stages of exposure, limiting the ability to validate model predictions in this range. We provide the adhesion energy measurements for EVA adhesion after nearly six years of field aging and 10 000 h of accelerated aging. Both field and accelerated aging reveal a distinct plateau that emerges during the intermediate exposure periods (after one year in the field and after 1000 h in a chamber). At 10 000 h, adhesion within accelerated aged minimodules falls to a level generally seen after long-term field exposures (>15 years). Previous modeling predicted that adhesion would steadily decrease over the lifetime of a module, but these current results uncover an intermediate plateauing trend that is important to accurately modeling the evolution of adhesion and predicting adhesive failure. Based on these findings, three key model refinements concerning the rate of UV-radical formation and subsequent β-scission, the rate and acceleration of hydrolytic depolymerization, and the profile of the plasticity contribution over time are implemented and discussed.

14 SOLAR ENERGY↗
DOE OSTI2022

Managing Power Systems-Induced Wildfire Risks Using Optimal Scheduled Shutoffs

The increasing demands for electricity and the increase in extreme weather conditions are putting unprecedented pressure on our electric grids. Often, this pressure leads to electrical component failures, which might ignite wildfires. This work develops a novel model to balance the reliability of power network operations and the risk of wildfire ignition by opti- mizing the operational schedule of power transmission networks considering time-varying risk measures that include exogenous and operational factors. Energy storage systems are considered to deliver power during peak wildfire hours and enable temporal load shifting. The problem is formulated as a mixed-integer linear program that maximizes a weighted sum of the served power demand and the reduction in grid-induced wildfire risk. The results demonstrate the ability of the model to significantly reduce wildfire risk without considerable load shedding.

power systems operations↗
DOE OSTI2025

Anomaly Detection in Seismic Data with Deep Learning: Application for Instrument Failure Detection and Forecasting

Seismic data quality assessment (QA) is the first and one of the most important steps before conducting any further data analysis. Traditional methods involve checking various metrics, such as spike detection and power spectral density, by setting strict thresholds or comparing data against synthetic benchmarks. However, these approaches often rely on pre-existing knowledge and assumptions about data anomalies, leading to potential misclassification of unusual cases. Here, in this study, we propose a deep autoencoder model, an unsupervised learning approach that evaluates data quality without making assumptions about normal and anomalous data, which can be used to identify deviations in recorded data that may indicate nascent instrument failure. We test the model with the U.S. International Monitoring System (IMS) seismic stations and demonstrate the capability of detecting anomalies on a monthly scale. This could prompt station operators to examine potential problems early, allowing sufficient time for instrument maintenance to prevent data outages. In addition, we use a new manually selected testing dataset to compare our model performance against two supervised machine learning (ML) approaches and a standard QA package, as baseline models. When applied to the dataset containing known data anomalies, performance of the supervised and unsupervised ML approaches is similar, with an accuracy of 88.1% for our model compared to ∼90% for the supervised ML approach and 78.2% for the standard QA package. Our model outperforms the baseline models when applied to new stations, where new types of data anomalies can be station-specific and not included in the training dataset. Finally, we show model transferability by training the model with data from the Global Seismograph Network only and applying it to the IMS network data. The results suggest that our model is generalizable and can be applied to new stations with good accuracy.

Lin, Jiun-Ting [Lawrence Livermore National Labora↗
DOE OSTI2025

Euro-Deterrent: Analysis of Proposals for a European Nuclear Arsenal (CNSIS Paper)

The idea of a “Euro-deterrent”—a nuclear arsenal under European control and mandated to protect multiple European countries—has been proposed many times as a means for European self-defense independent of United States security guarantees under the North Atlantic Treaty Organization (NATO). This paper examines not only the concept’s multiple guises, but the reasons for their failure. It will address the idea of a Franco-British umbrella, a French umbrella, a European “pool”, and the nuclear arsenal of a hypothetical “united Europe”. Reasons for rejection largely fall into three categories: sovereignty concerns, credibility gaps, and a desire to preserve existing norms and structures. This paper concludes that the Euro-deterrent will likely remain only hypothetical unless the US unequivocally signals its intent to withdraw its nuclear umbrella from Europe, thereby forcing European countries to build a new defense arrangement.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2026

Adaptive Cybersecurity for Distributed Energy Resources (AdCyDER): Online Reinforcement Learning with Stackelberg-Optimized Defenses — Pipeline Architecture, Evaluation Methodology, and Findings from a Synthetic-Data Evaluation

This report documents the design and evaluation of an integrated online-learning pipeline developed within the AdCyDER project for Distributed Energy Resource (DER) cybersecurity. The pipeline couples a Reinforcement Learning (RL) attack classifier — which produces an attack-type probability distribution — with a Stackelberg game-theoretic (GT) defense selector that consumes those distributions alongside SME-encoded priors over (defense, attack) effectiveness pairings and perdefense costs to choose grid-health-preserving defenses. The objective is not attack classification per se but production of distributions that drive effective defense selection through the Stackelberg layer, learned from delayed grid-health feedback rather than labeled attack data. AdCyDER as a whole is broader than the work presented here; this report covers the specific RL/GT loop integration and its evaluation. We present the integrated pipeline (SCADA telemetry with Fronius inverter physics, Suricata IDS, time-windowed aggregation, per-facility LSTM classifier, Stackelberg optimizer, OpenC2 actuators), an experimental campaign of 28 eight-hour iterations across three baseline modes, and a pipeline-ordered diagnostic protocol. The protocol identifies two distinct failure modes within the loop: paired supervised ceilings on the same features establish that the deployed online RL classifier (macro F1 ≈ 0.07) sits at least 4.7× below a same-architecture supervised LSTM (≈ 0.34) and 10–11× below a linear feature-signal ceiling (≈ 0.70–0.79 depending on per-facility isolation), localizing the dominant failure to the training procedure; and the reward signal driving online updates carries weak directional coupling with classifier correctness in the methodology-expected direction (multi-lens convergent: top-decile P(true) records produce more frequent state changes and slightly larger improvements, top-vs-bot Cohen’s 𝑑 ≈ −0.19), but at effect magnitudes too small to drive gradient-based learning at the campaign sample size. The original learning hypothesis is not supported by the data. The primary contributions are the diagnostic methodology — proposed as a transferable falsification protocol for online RL/GT defense pipelines learning from delayed environmental reward — and the open, reproducible experimental infrastructure. We outline reward reformulation as the highest-priority aspirational next step given the underpowered-but-aligned Q6 reading, with hardware-in-the-loop evaluation as the broadest scope-expansion option.

Blakely, Benjamin [Argonne National Laboratory (AN↗
DOE OSTI2024

Evaluation of 304L stainless steel deformation and failure under cyclic loading

The motivation for this work came from the simulation of components subjected to impact. In these problems, repeated loading can be generated by vibrational motion between internal parts of the component or by the occurrence of multiple impacts. Graphs of tensile equivalent plastic strain $(\overline{\varepsilon}_T^\rho)$ versus time from such cases had the character shown in Fig. 1. The equivalent plastic strain grew by alternating periods of accumulation and hold. The periods of hold indicate times when $d\overline{\varepsilon}_T^\rho$ did not accumulate. This can be due to the material unloading into the elastic range, or actually plastically reverse loading with hydrostatic stress σ h < 0 as was demonstrated for an impact simulation. Similar observations were made from the simulation of a 2-degree-of-freedom mass-elastic-plastic-spring system subjected to impact.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cost Efficient and Highly Weather-Resistant Solar Panel Backsheet Produced through Continuous Co-Extrusion Processing

The efficient generation and delivery of ‘clean energy” through photovoltaic (PV) technology relies heavily on the cost, performance and reliability of solar panels, along with the individual components used in assembly of those panels. In order to continue towards the Department of Energy’s (DOE) goals of driving costs down, the lifetime of high-output power generation equipment (i.e. solar modules) must be extended to reduce costs associated with power output degradation and replacement of failed or degraded panels. One of the major sources of module failures in the past 30 years has been the failure of the solar panel backsheet. Failure of this component causes severe output losses due to oxidation and yellowing of the module while creating safety concerns as the major electrical insulation of the module is compromised. Tomark-Worthen LLC was formed in 2012 with the goal of designing and manufacturing novel PV backsheets and encapsulants that would be produced in the United States of America and exceed expectations of domestic and international module producers. These backsheets would improve upon known backsheet design failures (i.e. Isovoltaic’s AAA backsheet) and create domestic manufacturing jobs in the PV sector. This goal became a reality with a first-generation product in 2018 and now, with the support of the DOE, Tomark-Worthen has launched a second-generation product known as PhotoMark® Reflections™ 205-3 and 360-3. This 2+ year effort began in late 2017 with a screening of potential polymeric materials and backsheet structural designs. Performance evaluations of each material provided the necessary data needed to select the proper material combinations and move forward into the design of the manufacturing process. These decisions were made by teaming with a local university, well-respected government laboratories, and private research organizations who provided the tools necessary to predict long-term performance of these materials in much shorter periods of time. Once the go/no-go criteria were met at the mid-point of the project, the effort transitioned to predicting 30+ year performance, achieving certifications, and improving manufacturing efficiencies designed to lower costs in order to be competitive in a cost-driven market. Major project accomplishments include recognition of the new backsheet by Underwriters Laboratories (UL) and international certification for 1000V and 1500V modules by TUV Sud. Both 1000V and 1500V products have been proven on several module manufacturing lines and initial customer orders have been received by both domestic and international module producers. Accelerated exposure testing has shown that the performance of this backsheet exceeds the prior polyamide-based backsheet known to fail in the field. Cost-models and initial customer orders have shown the ability to produce this backsheet at a cost acceptable to many domestic manufacturers, while International costs for standard backsheet remains extremely low. Tomark-Worthen remains one of the only U.S. companies manufacturing backsheet domestically and this has drawn interest from many domestic module manufacturers looking to improve their material supply logistics by avoiding long lead times and custom’s headaches while avoiding current tariffs on Chinese-made components. Along with the launch of a new PV backsheet, this project has provided a critical deliverable to the PV R&D community. This deliverable is the knowledge that not all polyamide-containing backsheets are doomed to failure as the earlier versions did. There has been a fear amongst the PV community to consider these materials due to the failure of one design. This effort has brought a new level of interest to the scientific community as it has been shown that polyamides can be used successfully in a well-designed backsheet. As we move forward from this project, we are excited to see how backsheet technology and manufacturing in the U.S. will continue to progress and grow.

14 SOLAR ENERGY↗
DOE OSTI2022

Demonstrating Distribution System Resiliency through Grid-Edge Microgrids, on a Multi-Site Networked Hardware-in-Loop Platform

With the increasing penetration of Distributed Energy Resources (DERs) at the grid-edge, power systems include more energy storage, remote switches, relays, voltage regulators, and other intelligent electronic devices (IED). Effective control of these grid-edge devices by using Advanced Distribution Management Systems (ADMS) can yield substantial improvements to the resiliency and power quality of distribution systems. In this paper, improvements to the resiliency of a distribution system are demonstrated using a multi-site evaluation environment consisting of a real-time Hardware-in-Loop (HIL) setup in which DERs and other IEDs are modeled; and an ADMS which monitors and is able to control the distribution system assets. The HIL model and the ADMS are located 2400 km away, with communication between the sites enabled by a data manager using Distributed Network Protocol 3 (DNP3), demonstrating the system's capabilities even over long distances. After a simulated transmission system failure in the HIL demonstration setup, DERs and other devices are operated to restore critical loads and node voltage profile (to within the 'nominal +/-5%' band) in the distribution system.

ADMS↗
DOE OSTI2023

Disjunctive optimization model and algorithm for long-term capacity expansion planning of reliable power generation systems

This paper proposes a new optimization model and algorithm for long-term capacity expansion planning of reliable power generation systems. The model optimizes both investment decisions (e.g., size, location, and time to install, retire and decommission facilities) and operation decisions (e.g., on/off status, operating capacity, and expected power output). It is also able to optimize reserve systems (or backup systems), as well as the main systems, to improve power systems reliability. An impact of operational strategies of generators (i.e., participating in electricity production vs. remaining as idle units during operation) on power systems reliability is considered. Probability of equipment failures and capacity failure states are used to rigorously estimate the power systems reliability depending on design and operation strategies. The optimization model is formulated with Generalized Disjunctive Programming (GDP), which is reformulated as a mixed-integer linear programming (MILP) model using the Hull relaxation. Two reliability-related penalties, such as downtime penalty and unmet demand penalty, are included in the objective function to maximize reliability while minimizing the total net present cost. Furthermore, a bilevel decomposition with tailored cuts is developed to reduce computational times of the multi-scale optimization model. The effectiveness of the proposed model is shown by comparing the results with the results obtained from the expansion planning models that do not explicitly consider reliability. In conclusion, we also show that the proposed bilevel decomposition is computationally efficient for solving large scale problems through 5-years and 10-years planning case studies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗