Results for “flexible operation” — Page 78

DOE OSTI2021

VERAIO Software Management Plan

VERAIO is a set of utility codes used to provide a common set of input and outputs to the Virtual Environment for Reactor Applications (VERA). VERA is a collection of several different computer codes that all have a common input and output. This prevents the need to manage input and output from each individual code, allowing for ease of use and reducing errors associated with code operability. The VERAIO utilities include VERAIn, VERAView, and VERARun. Each of these utilities is described below. VERAIn is an input processor that reads an ASCII input file generated by users, parses the file, performs some error checking, and writes an XML file to be read by other VERA codes. The main purpose of VERAIn is to provide a common input to all of the VERA codes so users only need to learn one input. VERAIn is written in Perl and uses YAML configuration files to provide flexibility. VERAView is a graphical user interface (GUI) that reads a VERA HDF output file and allows users to visualize results. VERAView is written in Python. VERARun is a script that drives the VERA execution in a high performance computing (HPC) environment. Work performed at the code level supports the Quality Assurance Program Plan (QAPP) (VERA-QA-001), and VERA Software Quality Assurance Plan (VERA-QA-002).

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

VERAIO Software Management Plan

VERAIO is a set of utility codes used to provide a common set of inputs and outputs to the Virtual Environment for Reactor Applications (VERA). VERA is a collection of several different computer codes that all have a common input and output. This prevents the need to manage input and output from each individual code, allowing for ease of use and reducing errors associated with code operability. The VERAIO utilities include VERAIn, VERAView, and VERARun. Each of these utilities is described below. VERAIn is an input processor that reads an ASCII input file generated by users, parses the file, performs some error checking, and writes an XML file to be read by other VERA codes. The main purpose of VERAIn is to provide a common input to all of the VERA codes, so users only need to learn one input. VERAIn is written in Perl and uses YAML configuration files to provide flexibility. VERAView is a graphical user interface (GUI) that reads a VERA hierarchical data format (HDF) output file and allows users to visualize results. VERAView is written in Python. VERARun is a script that drives the VERA execution in a high performance computing (HPC) environment. Work performed at the code level supports the quality assurance program plan (QAPP) (VERA-QA-001) and the VERA Software Quality Assurance Plan (VERA-QA-002).

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

42 ENGINEERING↗

DOE OSTI2020

The Cloud-resolving model Radar SIMulator (CR-SIM) Version 3.3: description and applications of a virtual observatory

Ground-based observatories use multi-sensor observations to characterize cloud and precipitation properties. One of the challenges is how to design strategies to best use these observations to understand these properties and evaluate weather and climate models. This paper introduces the Cloud resolving model Radar SIMulator (CR-SIM), which uses output from high-resolution cloud resolving models (CRMs) to emulate multi-wavelength, zenith-pointing, and scanning radar observables and multi-sensor (radar and lidar) products. CR-SIM allows direct comparison between an atmospheric model simulation and remote-sensing products using a forward-modeling framework consistent with the microphysical assumptions used in the atmospheric model. CR-SIM has the flexibility to easily incorporate additional microphysical modules, such as microphysical schemes and scattering calculations, and expand the applications to simulate multi-sensor retrieval products. In this paper, we present several applications of CR-SIM for evaluating the representativeness of cloud microphysics and dynamics in a CRM, quantifying uncertainties in radar-lidar integrated cloud products and multi-Doppler wind retrievals, and optimizing radar sampling strategy using observing system simulation experiments. These applications demonstrate the application of CR-SIM as a virtual observatory operator on high-resolution model output for a consistent comparison between model results and observations to aid interpretation of the differences and improve understanding of the representativeness errors due to the sampling limitations of the ground-based measurements. CR-SIM is licensed under the GNU GPL package and both the software and the user guide are publicly available to the scientific community.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

A Methodology for Measuring Blade Clearance on an Operating Utility-Scale Wind Turbine

This report describes the deployment of eleven laser sensors to measure the clearance between blades and tower in a 1.5-MW wind turbine whose rotor was mounted first in upwind and then in downwind configurations. The experimental recordings are compared to the numerical predictions generated by an aeroservoelastic model of the turbine. Good agreement is found between the two datasets, although discrepancies up to 30~cm are observed. The sources of this error are discussed. This methodology is found to be a valuable resource for the validation of the numerical predictions of the flapwise deflections of wind turbine blades. The accurate prediction of these deflections is increasingly important as wind turbines grow in size and become increasingly flexible.

17 WIND ENERGY↗

DOE OSTI2024

Flexible Ramping Product Procurement in Day-Ahead Markets

Flexible ramping products (FRPs) emerge as a promising instrument for addressing steep and uncertain ramping needs through market mechanisms. Initial implementations of FRPs in North American electricity markets, however, revealed several shortcomings in existing FRP designs. Here, in many instances, FRP prices failed to signal the true value of ramping capacity, most notably evident in zero FRP prices observed in a myriad of periods during which the system was in acute need for rampable capacity. These periods were marked by scheduled but undeliverable FRPs, often calling for operator out-of-market actions. On top of that, the methods used for procuring FRPs have been primarily rule-based, lacking explicit economic underpinnings. In this paper, we put forth an alternative framework for FRP procurement, which seeks to set FRP requirements and schedule FRP awards such that the expected system operation cost is minimized. Using real-world data from U.S. ISOs, we showcase the relative merits of the framework in (i) reducing the total system operation cost, (ii) improving price formation, (iii) enhancing the the deliverability of FRP awards, and (iv) reducing the need for out-of-market actions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Status of EM Pump Modeling Capability for VTR

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analyses of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. Most recently, SAS4A/SASSYS-1 has been selected as the safety analysis software for the Versatile Test Reactor (VTR), a new materials testing Sodium Fast Reactor (SFR) to be built by the Department of Energy. In order to support analysis of the VTR, which will utilize ElectroMagnetic (EM) pumps as the primary coolant pumps, the development of new EM pump modeling capabilities has been initiated for SAS4/SASSYS-1. The new physics-based EM pump model captures systems-level transient performance based on equivalent circuit theory and is highly flexible to model a wide range of electromagnetic pumps of the three-phase linear induction type subject to changes in power supply and plant conditions. Within the equivalent circuit framework, two sub-models are developed to provide options for analysts both with and without a detailed geometric characterization of their pump such that minimal information is required to achieve a realistic working model, but specific details of a particular pump design may be captured if sufficient information is provided. In addition, heat generated from pump operation and its transport through the plant system can be modeled to better capture the behavior of certain transients. This paper will outline the model and derive the governing equations of the new EM pump model. An initial comparison between the simple EM pump model and experimental data is made. This comparison shows that the equivalent circuit model can capture pump performance, with greater accuracy near the rated conditions. In order to demonstrate the transient behavior of the new model, a simple transient with an EM pump replacing the centrifugal pumps in the Advanced Burner Test Reactor is included.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Status of EM Pump Modeling Capability for VTR

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analyses of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. Most recently, SAS4A/SASSYS-1 has been selected as the safety analysis software for the Versatile Test Reactor (VTR), a new materials testing Sodium Fast Reactor (SFR) to be built by the Department of Energy. In order to support analysis of the VTR, which will utilize ElectroMagnetic (EM) pumps as the primary coolant pumps, the development of new EM pump modeling capabilities has been initiated for SAS4/SASSYS-1. The new physics-based EM pump model captures systems-level transient performance based on equivalent circuit theory and is highly flexible to model a wide range of electromagnetic pumps of the three-phase linear induction type subject to changes in power supply and plant conditions. Within the equivalent circuit framework, two sub-models are developed to provide options for analysts both with and without a detailed geometric characterization of their pump such that minimal information is required to achieve a realistic working model, but specific details of a particular pump design may be captured if sufficient information is provided. In addition, heat generated from pump operation and its transport through the plant system can be modeled to better capture the behavior of certain transients. This paper will outline the model and derive the governing equations of the new EM pump model. An initial comparison between the simple EM pump model and experimental data is made. This comparison shows that the equivalent circuit model can capture pump performance, with greater accuracy near the rated conditions. In order to demonstrate the transient behavior of the new model, a simple transient with an EM pump replacing the centrifugal pumps in the Advanced Burner Test Reactor is included.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

New Advances in Optical Stochastic Cooling

Recently, Optical Stochastic Cooling (OSC) became the first demonstrated method for ultra-high-bandwidth stochastic cooling. The initial experiments at Fermilab’s IOTA ring explored the essential physics of the method and demonstrated cooling, heating and manipulation of beams and single particles. Having been validated in practice, with continued development, OSC carries the potential for dramatic advances in the state-of-the-art performance and flexibility for beam cooling and control. The ongoing program at Fermilab is now focused on the development of an OSC system that includes high-gain optical amplification, which promises a two-order-of-magnitude increase in the strength of the OSC force. In this talk, we briefly review the results of the initial experimental campaign, describe the status of the conceptual and hardware designs for the amplified OSC system, report initial experimental results of our high-gain amplifier development, and explore near-term operational plans and use cases.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Developing Smart Building Technology Modules to Enhance Workforce Preparedness: A Case for AI-Driven Academic and Professional Education

Smart building technologies are resources that improve building energy efficiency and resilience, reduce carbon emissions, and provide load flexibility to the grid. However, in both academic curricula and building professionals’ continuing education, there is a lack of systematic instruction on methods to integrate multiple energy systems including distributed energy resources (DER), smart building technologies, AI (Artificial Intelligence) tools and key concepts, components, and controls, including “Internet of Things” (IoT) devices. In today’s dynamic workforce, this major gap in smart building technology education prevents stakeholders from being able to attract talent with an understanding and preparation to adopt smart building technologies in building design and operations. A federally funded project included a partnership between Slipstream and Texas A&M University (TAMU) to develop a semester-long smart building curriculum for engineering college students with the ability to adapt the contents for workforce development of professionals in building services. The final product consists of 16 training videos adapted for building professionals and the public. The educational content and training materials cover the benefits of building energy systems, the latest sensor technologies and IoT devices, all with a focus on smart building technologies. The key drivers are on topics related to smart building controls (i.e., energy management information systems), smart building control platforms, cybersecurity, grid-interactive-efficient buildings (GEBs), smart building control methods, and occupant-centric control. Although not explicitly included the technologies nod to the need for AI driven technologies to prepare engineers and industry professionals to be future ready. This paper describes the project approach, provides outlines of the training materials, and identifies lessons learned in creating the content for this course. The authors suggest ways to scale the instruction of smart building concepts to empower the workforce to accelerate the adoption of smart building technologies and AI-based teaching and learning in higher education and building sector.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

A discontinuous Galerkin spectral element method for compressible reacting flows

High-order methods have recently been shown to be an effective tool for high-fidelity flow computations like direct numerical simulations and large-eddy simulations because of their strong balance between accuracy and computational cost. In this work, a high-order discontinuous Galerkin spectral element method (DGSEM) is developed to solve the chemically reacting Navier-Stokes equations. To handle the disparate length and time scales associated with these equations, we develop a novel method which combines the spectral accuracy of the SEM with the flexibility of the DG approach. The framework, implemented in the spectral element code Nek5000, is well suited to capture turbulence in smooth regions of the flow, while maintaining numerical stability in the presence of shocks. An entropy-residual based artificial viscosity is added to smooth shocked regions of flow, and a positivity-preserving limiter is implemented to suppress non-physical oscillations. These enhancements support the numerical stability of the hydrodynamic sub-step, which is decoupled from the chemistry integration through a second-order operator splitting method. Here, a series of smooth and discontinuous validation cases are presented in increasing physical and computational complexity for both inviscid and viscous flows. In particular, simulations of canonical one-dimensional and two-dimensional detonations are performed, and the high-order numerical results are validated against available literature data. Additional validation studies are carried out for classical three-dimensional numerical simulations of incompressible and compressible turbulent flows.

Compressible reacting flows↗

DOE OSTI2020

Making coal relevant for small scale applications: Modular gasification for syngas/engine CHP applications in challenging environments

Small-scale coal gasification technology, coupled to a reciprocating engine generator, has the potential for making coal a cost competitive resource for meeting the flexible energy needs and resiliency requirements of utilities across the United States. To maintain grid stability and reliability, electrical generation must be regulated to match the load at the proper voltage and frequency. With the expansion of intermittent sources into the grid, such as wind and solar, frequency and voltage regulation become increasingly important and challenging. This work presents the results of a Front End Engineering Design (FEED) effort to detail the engineering and preliminary economics of a small-scale, air blown, fixed-bed gasification process, operating at near-atmospheric pressure, with gas cleanup to provide syngas and pyrolysis liquid fuels for use in reciprocating engine generators for combined heat and power at the University of Alaska Fairbanks. A very detailed assessment of capital and operating costs allows the evaluation of a levelized cost of electricity of 208.06 $/MWh, which can be reduced through the selling of by-products (steam for heating purposes and pyrolysis liquids to be used for power generation in an existing diesel engine). Here, a combined sensitivity analysis, based on the Monte Carlo approach, has been carried out to evaluate the effects of the uncertainties (capital and operating costs and plant annual availability) on the LCOE.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

A performance comparison between GaInP-on-Si and GaAs-on-Si 3-terminal tandem solar cells

The pursuit of ever-higher solar cell efficiencies has focused heavily on multijunction technologies. In tandem cells, subcells are typically either contacted via two terminals (2T) or four terminals (4T). Simulations show that the less-common three-terminal (3T) design may be comparable to 4T tandem cells in its compatibility with a range of materials, operating conditions, and methods for subcell integration, yet the 3T design circumvents shading losses of the 4T intermediate conductive layers. This study analyzes the performance of two superstrate 3T III-V-on-Si (III-V//Si) tandem cells: One has slightly greater current contribution from the Si bottom cell (GaInP//Si) and the other has substantially greater current contribution from the GaAs top cell (GaAs//Si). Our results show that both tandem cells exhibit the same efficiency (21.3%), thereby demonstrating that the third terminal allows for flexibility in the selection of the top cell material, similar to the 4T design.

14 SOLAR ENERGY↗

DOE OSTI2024

Enhanced performance of Bi 2 S 3 /TiO 2 heterostructure composite films for solar cell applications

Day to day energy production is shifting towards renewable energy sources as these sources become more economically viable while being less polluting to operate; solar energy has become one of the major sources of renewable energy. However, it currently relies on ultra-pure silicon ingots to produce commercial silicon photovoltaics, which prevents the cost of electricity being produced to compete with non-renewable energy production. A viable low-cost alternative for silicon based cells would be dye-sensitized solar cells (DSSCs), which are easier and cheaper to manufacture as they do not require expensive and delicate raw materials to make. Moreover, they could be made semi-flexible which allows for a greater variety of applications. A DSSC consists of three components, a photo-electrode, an electrolyte and a counter-electrode. When exposed to incident light, the complex photosensitizers in the photoelectrode release electrons which are transported to the external load, leaving the photoelectrode in an oxidized state. The electrons are collected by the counter electrode and used to reduce the electrolyte. This charged electrolyte then reduces the positively charged photoelectrode, allowing the process to begin again. To improve the efficiency of this process, we explore the use of bismuth sulfide (Bi 2 S 3 ) and titanium oxide (TiO 2 ) composite as photoelectrode material and investigate their impact on the efficiency of DSSC.

14 SOLAR ENERGY↗

DOE OSTI2024

Flexible silicon photonic architecture for accelerating distributed deep learning

The increasing size and complexity of deep learning (DL) models have led to the wide adoption of distributed training methods in datacenters (DCs) and high-performance computing (HPC) systems. However, communication among distributed computing units (CUs) has emerged as a major bottleneck in the training process. In this study, we propose Flex-SiPAC, a flexible silicon photonic accelerated compute cluster designed to accelerate multi-tenant distributed DL training workloads. Flex-SiPAC takes a co-design approach that combines a silicon photonic hardware platform with a tailored collective algorithm, optimized to leverage the unique physical properties of the architecture. The hardware platform integrates a novel wavelength-reconfigurable transceiver design and a micro-resonator-based wavelength-reconfigurable switch, enabling the system to achieve flexible bandwidth steering in the wavelength domain. The collective algorithm is designed to support reconfigurable topologies, enabling efficient all-reduce communications that are commonly used in DL training. The feasibility of the Flex-SiPAC architecture is demonstrated through two testbed experiments. First, an optical testbed experiment demonstrates the flexible routing of wavelengths by shuffling an array of input wavelengths using a custom-designed spatial-wavelength selective switch. Second, a four-GPU testbed running two DL workloads shows a 23% improvement in job completion time compared to a similarly sized leaf-spine topology. We further evaluate Flex-SiPAC using large-scale simulations, which show that Flex-SiPAC is able to reduce the communication time by 26% to 29% compared to state-of-the-art compute clusters under representative collective operations.

Wu, Zhenguo (ORCID:0000000322847985)↗

DOE OSTI2023

Development and testing of residential micro-CHP powered by opposed piston engine (CRADA Final Report)

A micro–combined heat and power (mCHP) prototype powered by innovative opposed piston engine technology was developed to simultaneously provide electricity and heat to residential or light commercial buildings. The mCHP prototype targeted at residential applications includes an opposed-piston four-stroke (OP4S) engine, generator, rectifier, inverter, battery energy storage system, 52 gal water tank, and application accessories for hot water supply and space heating. The OP4S engine can use renewable or regular natural gas, as well as hydrogen, to generate mechanical power and waste heat in form of hot coolant and exhaust gas simultaneously. The waste heat is recovered and stored in the water tank and can be used as a regular hot water supply and/or for space heating application. The tests show that the mCHP prototype enabled power outputs in the range of 3.2 –7.4 kW with up to 26.4% of AC electricity efficiency and up to 93.1% of the overall mCHP efficiency under stoichiometric combustion modes λ=~1.0. The mCHP was also run under lean combustion mode conditions at λ=~1.3. The lean mode operation enables more than 30% improvement in electrical energy efficiency. The maximum AC efficiency of the lean combustion mode attained was 35.2%, with the engine efficiency is approaching 40%. The exceptional electrical efficiency breaks the typical upper boundary of 30% for ICE-based mCHP. The engine exhaust temperatures in the lean modes are substantially less than in the stoichiometric modes. Moreover, the lean cases achieve high overall mCHP efficiencies: the overall mCHP efficiencies are all greater than 93%. Considering the mCHP prototype can achieve low-cost, flexible matching of thermal and electrical loads through reducing the complexity of distribution and installation, and high efficiency the novel technology will promote mCHP acceptance in the US residential and light commercial markets.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Progressing Analysis of Variable Electric Rates (PAVER) Study

The Progressing Analysis of Variable Electric Rates (PAVER) study analyzed the impact of a range of time-varying electric rates on the performance of a regional electric grid and the resulting costs for participating and non-participating customers. This analysis leveraged and extended the work of PNNL’s Distribution System Operator with Transactive (DSO+T) study. Five different rate designs were included: a flat volumetric energy charge, a typical Time of Use (TOU) rate, a dynamic energy (DE) rate (based on wholesale locational marginal prices), a dynamic energy and capacity (DE+C) rate, and, finally, a Block and Swing (B&S) rate that billed customers based on their average load profile at constant pricing, but used the DE+C dynamic price for load deviations from their average profile. These rates were analyzed in a large-scale co-simulation of an entire regional grid with a customer population representative of the current state. A large fraction (80%) of residential and commercial customers were assumed to participate in these time-varying rates with automatically controlled HVAC, water heaters, electric vehicles, and batteries. This study assumed no industrial sector participation. The DE and DE+C rates saw system peak loads reduced by 6-7%, while the large participation in the TOU rate case saw a significant rebound effect and a resulting peak load increase of >5%. The impacts to the annual and peak system demand impacted system wholesale prices and the overall grid operating costs. This cost structure determined the revenue needed to be collected from customers by each rate design. Participating customers on the DE and DE+C rates (located in one of the modeled DSOs) saw reductions in average annual electricity bills of 11-17% with average increases in monthly bill variation of no more than 13%. At such high participation levels, TOU customers saw 10% higher average annual bills (due to system-wide rebound effects) and average increased monthly bill variation of 16%. Residential owners of large flexible loads (such as electric vehicles) saw larger bill savings (17-20%) when on a fully dynamic rate. The presence of on-site generation (such as rooftop solar) did not appear to appreciably change customer outcomes. Customers on the Block and Swing rate did see 6% lower monthly bill variation (as intended) than the flat rate case, but at the expense of appreciable bill savings, which were only 3%, comparable to the savings seen by non-participants. Given this finding we recommend that additional research be conducted into how best various bill protection mechanisms can balance minimizing customer bill variation with providing financial incentives commensurate with the flexibility customers provide. We also recommend that customer outcomes be explored across a range of regions using current actual customer and system cost data.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗