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DOE OSTI2021

OPERATING EXPERIENCE AND ITS RELATIONSHIP TO EMBEDDED DIGITAL DEVICES IN SAFETY SYSTEMS

Interest in embedded digital devices (EDDs) for monitoring and providing control of components is increasing and the added functionality digital brings such as diagnostics, displays, control functions is welcomed in both the nuclear and other industries. As a result, pure analog-based components continue to disappear from the industrial I&C marketplace. Equipment with EDDs, also known by related terms such as smart devices, intelligent devices, and digital devices of limited functionality, can include sensors, breakers, priority logic modules, time delay relays, pumps, valve actuators, motor control centers, and uninterruptible power supplies. Not only is equipment consisting of analog and older digital technology being replaced with commercial grade products containing EDDs, but EDDs can also be retrofitted to work with existing components. EDDs may be installed physically within a component, such as in a relay. There are also external devices that some would not consider an EDD, but that operate in almost all technical ways identically to one internal to a component such as in a valve controller. In fact, the digital portions may be located hundreds of feet from the actual component.Due to the potential of being used in an identical manner and without alteration from their application in other industries, operating experience (OpE) for EDDs may be much more applicable than in the case of other more system level devices. Clear separation and independence of functionality provided with EDDs may also allow greater applicability of existing OpE from industry for changes that can be shown not to affect its safety function. However, OpE also demonstrates issues with different conditions between other industries and nuclear power plants, such as issues with undeclared changes or undeclared digital devices and the new failure modes they may introduce, issues with the reporting of OpE in industry, and a lack of transparency into OpE for EDDs.Understanding and addressing these issues will be key in the future use of EDDs in nuclear power plants, but failure rate data is difficult to obtain for EDDs, and lessons learned from the use of EDDs are difficult to collect and identify.Key words: embedded digital device, smart device, operating experience, failure modes

Muhlheim, Michael↗

DOE OSTI2022

HERO WEC V1.0 - WEC-Sim Detailed Simulation Runs and Summary Data

Data sets from simulation runs include 144 wave cases that were run based on the WEC-Sim model (https://mhkdr.openei.org/submissions/483). The 144 wave cases represent waves with the following wave height and wave period ranges: - Significant Wave Height: 0.25 - 4.0m in 0.25m increments - Wave Period: 5 - 13 sec in 1 sec increments Each run was simulated using a Pierson-Moskowitz irregular wave spectrum with a 200 second ramp time and a total simulation time of 2,200 seconds. Summary data set includes a spreadsheet and image files with matrices that are associated with data from simulation runs. All matrices cover the same significant wave height and wave periods from the sim runs, in the same increments. The following matrices are included: - Mechanical Power Input: Absorbed power calculated using linear input velocity at PTO (power take-off) multiplied by winch tension. - Mechanical Power Output: The hydraulic power calculated at the pump output prior to the pressure relief valve dump. - Feed Pressure: Average pressure at RO (reverse osmosis) input prior to pre-filters - RO Power Input: The hydraulic power calculated at the RO system inlet, accounts for flow loss due to pressure relief valve - Water Production: Average clean water flow at RO output

16 TIDAL AND WAVE POWER↗

DOE OSTI2014

Updated Peach Bottom Model for MELCOR 1.8.6: Description and Comparisons

A MELCOR 1.8.5 model of the Peach Bottom Unit 2 or 3 has been updated for MELCOR 1.8.6. Primarily, this update involved modification of the lower head modeling. Three additional updates were also performed. First, a finer nodalization of the containment wet well was employed. Second, the pressure differential used by the logic controlling the safety relief valve actuation was modified. Finally, an additional stochastic failure mechanism for the safety relief valves was added. Simulation results from models with and without the modifications were compared. All the analysis was performed by comparing key figures of merit from simulations of a long-term station blackout scenario. This report describes the model changes and the results of the comparisons.

LTSBO↗

DOE OSTI2014

HYDRAULICS AND MIXING EVALUATIONS FOR NT-21/41 TANKS

The hydraulic results demonstrate that pump head pressure of 20 psi recirculates about 5.6 liters/min flowrate through the existing 0.131-inch orifice when a valve connected to NT-41 is closed. In case of the valve open to NT-41, the solution flowrates to HB-Line tanks, NT-21 and NT-41, are found to be about 0.5 lpm and 5.2 lpm, respectively. The modeling calculations for the mixing operations of miscible fluids contained in the HB-Line tank NT-21 were performed by taking a three-dimensional Computational Fluid Dynamics (CFD) approach. The CFD modeling results were benchmarked against the literature results and the previous SRNL test results to validate the model. Final performance calculations were performed for the nominal case by using the validated model to quantify the mixing time for the HB-Line tank. The results demonstrate that when a pump recirculates a solution volume of 5.7 liters every minute out of the 72-liter tank contents containing two acid solutions of 2.7 M and 0 M concentrations (i.e., water), a minimum mixing time of 1.5 hours is adequate for the tank contents to get the tank contents adequately mixed. In addition, the sensitivity results for the tank contents of 8 M existing solution and 1.5 M incoming species show that the mixing time takes about 2 hours to get the solutions mixed.

42 ENGINEERING↗

DOE OSTI2014

Polarized 3He Gas Circulating Technologies for Neutron Analyzers

We describe the development of an integrated system for quasi-continuous operation of a large volume neutron analyzer. The system consists of a non-magnetic diaphragm compressor, a prototype large volume helium polarizer, a surrogate neutron analyzer, a non-depolarizing gas storage reservoir, a non-ferrous valve manifold for handling gas distribution, a custom rubidium-vapor gas return purifier, and wire-wound transfer lines, all of which are immersed in a two-meter external magnetic field. Over the Phase II period we focused on three major tasks required for the successful deployment of these types of systems: 1) design and implementation of gas handling hardware, 2) automation for long-term operation, and 3) improvements in polarizer performance, specifically fabrication of aluminosilicate optical pumping cells. In this report we describe the design, implementation, and testing of the gas handling hardware. We describe improved polarizer performance resulting from improved cell materials and fabrication methods. These improvements yielded valved 8.5 liter cells with relaxation times greater than 12 hours. Pumping this cell with 1500W laser power with 1.25nm linewidth yielded peak polarizations of 60%, measured both inside and outside the polarizer. Fully narrowing this laser to 0.25nm, demonstrated separately on one stack of the four, would have allowed 70% polarization with this cell. We demonstrated the removal of 5 liters of polarized helium from the polarizer with no measured loss of polarization. We circulated the gas through a titanium-clad compressor with polarization loss below 3% per pass. We also prepared for the next phase of development by refining the design of the polarizer so that it can be engineer-certified for pressurized operation. The performance of our system far exceeds comparable efforts elsewhere.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2015

Development of a Versatile Ultrasonic Internal Pipe/Vessel Component Monitor for In-Service Inspection of Nuclear Reactor Components

The stated goal of this work was to develop a versatile system which could accurately measure vessel and valve internal vibrations and cavitation formation under in-service conditions in nuclear power plants, ultrasonically. The developed technology will benefit the nuclear power generation industry by allowing plant operators to monitor valve and vessel internals during operation. This will help reduce planned outages and plant component failures. During the course of this work, Structural Integrity Associates, Inc. gathered information from industry experts that target vibration amplitudes to be detected should be in the range of 0.001-in to 0.005-in (0.025-mm to 0.127-mm) and target vibration frequency ranges which should be detected were found to be between 0-Hz and 300-Hz. During the performed work, an ultrasonic measuring system was developed which utilized ultrasonic pulse-echo time-of-flight measurements to measure vibration frequency and amplitude. The developed system has been shown to be able to measure vibration amplitudes as low as 0.0008-in (0.020-mm) with vibration frequencies in the range of 17-Hz to 1000-Hz. Therefore, the developed system was able to meet the industry needs for vibration measurement. The developed ultrasonic system was also to be able to measure cavitation formation by monitoring the received ultrasonic time- and frequency-domain signals. This work also demonstrated the survivability of commercially available probes at temperatures up to 300-F for several weeks.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

Using Solar Hot Water to Address Piping Heat Losses in Multifamily Buildings

Solar thermal water heating is most cost effective when applied to multifamily buildings and some states offer incentives or other inducements to install them. However, typical solar water heating designs do not allow the solar generated heat to be applied to recirculation losses, only to reduce the amount of gas or electric energy needed for hot water that is delivered to the fixtures. For good reasons, hot water that is recirculated through the building is returned to the water heater, not to the solar storage tank. The project described in this report investigated the effectiveness of using automatic valves to divert water that is normally returned through the recirculation piping to the gas or electric water heater instead to the solar storage tank. The valves can be controlled so that the flow is only diverted when the returning water is cooler than the water in the solar storage tank.

ARBI↗

DOE OSTI2015

Using Solar Hot Water to Address Piping Heat Losses in Multifamily Buildings

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

Fuel Cell Balance-of-Plant Reliability Testbed Project

Reliability of the fuel cell system balance-of-plant (BoP) components is a critical factor that needs to be addressed prior to fuel cells becoming fully commercialized. Failure or performance degradation of BoP components has been identified as a life-limiting factor in fuel cell systems.1 The goal of this project is to develop a series of test beds that will test system components such as pumps, valves, sensors, fittings, etc., under operating conditions anticipated in real Polymer Electrolyte Membrane (PEM) fuel cell systems. Results will be made generally available to begin removing reliability as a roadblock to the growth of the PEM fuel cell industry. Stark State College students participating in the project, in conjunction with their coursework, have been exposed to technical knowledge and training in the handling and maintenance of hydrogen, fuel cells and system components as well as component failure modes and mechanisms. Three test beds were constructed. Testing was completed on gas flow pumps, tubing, and pressure and temperature sensors and valves.

08 HYDROGEN↗

DOE OSTI2016

Investigation of Natural Circulation Instability and Transients in Passively Safe Small Modular Reactors

The NEUP funded project, NEUP-3496, aims to experimentally investigate two-phase natural circulation flow instability that could occur in Small Modular Reactors (SMRs), especially for natural circulation SMRs. The objective has been achieved by systematically performing tests to study the general natural circulation instability characteristics and the natural circulation behavior under start-up or design basis accident conditions. Experimental data sets highlighting the effect of void reactivity feedback as well as the effect of power ramp-up rate and system pressure have been used to develop a comprehensive stability map. The safety analysis code, RELAP5, has been used to evaluate experimental results and models. Improvements to the constitutive relations for flashing have been made in order to develop a reliable analysis tool. This research has been focusing on two generic SMR designs, i.e. a small modular Simplified Boiling Water Reactor (SBWR) like design and a small integral Pressurized Water Reactor (PWR) like design. A BWR-type natural circulation test facility was firstly built based on the three-level scaling analysis of the Purdue Novel Modular Reactor (NMR) with an electric output of 50 MWe, namely NMR-50, which represents a BWR-type SMR with a significantly reduced reactor pressure vessel (RPV) height. The experimental facility was installed with various equipment to measure thermalhydraulic parameters such as pressure, temperature, mass flow rate and void fraction. Characterization tests were performed before the startup transient tests and quasi-steady tests to determine the loop flow resistance. The control system and data acquisition system were programmed with LabVIEW to realize the realtime control and data storage. The thermal-hydraulic and nuclear coupled startup transients were performed to investigate the flow instabilities at low pressure and low power conditions for NMR-50. Two different power ramps were chosen to study the effect of startup power density on the flow instability. The experimental startup transient results showed the existence of three different flow instability mechanisms, i.e., flashing instability, condensation induced flow instability, and density wave oscillations. In addition, the void-reactivity feedback did not have significant effects on the flow instability during the startup transients for NMR-50. ii Several initial startup procedures with different power ramp rates were experimentally investigated to eliminate the flow instabilities observed from the startup transients. Particularly, the very slow startup transient and pressurized startup transient tests were performed and compared. It was found that the very slow startup transients by applying very small power density can eliminate the flashing oscillations in the single-phase natural circulation and stabilize the flow oscillations in the phase of net vapor generation. The initially pressurized startup procedure was tested to eliminate the flashing instability during the startup transients as well. The pressurized startup procedure included the initial pressurization, heat-up, and venting process. The startup transient tests showed that the pressurized startup procedure could eliminate the flow instability during the transition from single-phase flow to two-phase flow at low pressure conditions. The experimental results indicated that both startup procedures were applicable to the initial startup of NMR. However, the pressurized startup procedures might be preferred due to short operating hours required. In order to have a deeper understanding of natural circulation flow instability, the quasi-steady tests were performed using the test facility installed with preheater and subcooler. The effect of system pressure, core inlet subcooling, core power density, inlet flow resistance coefficient, and void reactivity feedback were investigated in the quasi-steady state tests. The experimental stability boundaries were determined between unstable and stable flow conditions in the dimensionless stability plane of inlet subcooling number and Zuber number. To predict the stability boundary theoretically, linear stability analysis in the frequency domain was performed at four sections of the natural circulation test loop. The flashing phenomena in the chimney section was considered as an axially uniform heat source. And the dimensionless characteristic equation of the pressure drop perturbation was obtained by considering the void fraction effect and outlet flow resistance in the core section. The theoretical flashing boundary showed some discrepancies with previous experimental data from the quasi-steady state tests. In the future, thermal non-equilibrium was recommended to improve the accuracy of flashing instability boundary. As another part of the funded research, flow instabilities of a PWR-type SMR under low pressure and low power conditions were investigated experimentally as well. The NuScale reactor design was selected as the prototype for the PWR-type SMR. In order to experimentally study the natural circulation behavior of NuScale iii reactor during accidental scenarios, detailed scaling analyses are necessary to ensure that the scaled phenomena could be obtained in a laboratory test facility. The three-level scaling method is used as well to obtain the scaling ratios derived from various non-dimensional numbers. The design of the ideally scaled facility (ISF) was initially accomplished based on these scaling ratios. Then the engineering scaled facility (ESF) was designed and constructed based on the ISF by considering engineering limitations including laboratory space, pipe size, and pipe connections etc. PWR-type SMR experiments were performed in this well-scaled test facility to investigate the potential thermal hydraulic flow instability during the blowdown events, which might occur during the loss of coolant accident (LOCA) and loss of heat sink accident (LOHS) of the prototype PWR-type SMR. Two kinds of experiments, normal blowdown event and cold blowdown event, were experimentally investigated and compared with code predictions. The normal blowdown event was experimentally simulated since an initial condition where the pressure was lower than the designed pressure of the experiment facility, while the code prediction of blowdown started from the normal operation condition. Important thermal hydraulic parameters including reactor pressure vessel (RPV) pressure, containment pressure, local void fraction and temperature, pressure drop and natural circulation flow rate were measured and analyzed during the blowdown event. The pressure and water level transients are similar to the experimental results published by NuScale [51], which proves the capability of current loop in simulating the thermal hydraulic transient of real PWR-type SMR. During the 20000s blowdown experiment, water level in the core was always above the active fuel assemble during the experiment and proved the safety of natural circulation cooling and water recycling design of PWR-type SMR. Besides, pressure, temperature, and water level transient can be accurately predicted by RELAP5 code. However, the oscillations of natural circulation flow rate, water level and pressure drops were observed during the blowdown transients. This kind of flow oscillations are related to the water level and the location upper plenum, which is a path for coolant flow from chimney to steam generator and down comer. In order to investigate the transients start from the opening of ADS valve in both experimental and numerical way, the cold blow-down experiment is conducted. For the cold blowdown event, different from setting both reactor iv pressure vessel (RPV) and containment at high temperature and pressure, only RPV was heated close to the highest designed pressure and then open the ADS valve, same process was predicted using RELAP5 code. By doing cold blowdown experiment, the entire transients from the opening of ADS can be investigated by code and benchmarked with experimental data. Similar flow instability observed in the cold blowdown experiment. The comparison between code prediction and experiment data showed that the RELAP5 code can successfully predict the pressure void fraction and temperature transient during the cold blowdown event with limited error, but numerical instability exists in predicting natural circulation flow rate. Besides, the code is lack of capability in predicting the water level related flow instability observed in experiments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

The SAS4A/SASSYS-1 Safety Analysis Code System, Version 5

The SAS4A/SASSYS-1 computer code is developed by Argonne National Laboratory for thermal, hydraulic, and neutronic analysis of power and flow transients in liquidmetal- cooled nuclear reactors (LMRs). SAS4A was developed to analyze severe core disruption accidents with coolant boiling and fuel melting and relocation, initiated by a very low probability coincidence of an accident precursor and failure of one or more safety systems. SASSYS-1, originally developed to address loss-of-decay-heat-removal accidents, has evolved into a tool for margin assessment in design basis accident (DBA) analysis and for consequence assessment in beyond-design-basis accident (BDBA) analysis. SAS4A contains detailed, mechanistic models of transient thermal, hydraulic, neutronic, and mechanical phenomena to describe the response of the reactor core, its coolant, fuel elements, and structural members to accident conditions. The core channel models in SAS4A provide the capability to analyze the initial phase of core disruptive accidents, through coolant heat-up and boiling, fuel element failure, and fuel melting and relocation. Originally developed to analyze oxide fuel clad with stainless steel, the models in SAS4A have been extended and specialized to metallic fuel with advanced alloy cladding. SASSYS-1 provides the capability to perform a detailed thermal/hydraulic simulation of the primary and secondary sodium coolant circuits and the balance-ofplant steam/water circuit. These sodium and steam circuit models include component models for heat exchangers, pumps, valves, turbines, and condensers, and thermal/hydraulic models of pipes and plena. SASSYS-1 also contains a plant protection and control system modeling capability, which provides digital representations of reactor, pump, and valve controllers and their response to input signal changes.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

Status Report on the High-Temperature Steam Electrolysis Plant Model Developed in the Modelica Framework (FY17)

This report has been prepared as part of an effort to design and build a modeling and simulation (M&S) framework to assess the economic viability of a nuclear-renewable hybrid energy system (N-R HES). In order to facilitate dynamic M&S of such an integrated system, research groups in multiple national laboratories have been developing various subsystems as dynamic physics-based components using the Modelica programming language. In fiscal year 2015 (FY15), Idaho National Laboratory (INL) performed a dynamic analysis of two region-specific N-R HES configurations, including the gas-to-liquid (natural gas to Fischer-Tropsch synthetic fuel) and brackish water reverse osmosis desalination plants as industrial processes. In FY16, INL developed two additional subsystems in the Modelica framework: (1) a high-temperature steam electrolysis (HTSE) plant as a high priority industrial plant to be integrated with a light water reactor (LWR) within an N-R HES and (2) a gas turbine power plant as a secondary energy supply. In FY17, five new components (i.e., a feedwater pump, a multi-stage compression system, a sweep-gas turbine, flow control valves, and pressure control valves) have been incorporated into the HTSE system proposed in FY16, aiming to better realistically characterize all key components of concern. Special attention has been given to the controller settings based on process models (i.e., direct synthesis method), aiming to improve process dynamics and controllability. A dynamic performance analysis of the improved LWR/HTSE integration case was carried out to evaluate the technical feasibility (load-following capability) and safety of such a system operating under highly variable conditions requiring flexible output. The analysis (evaluated in terms of the step response) clearly shows that the FY17 model resulted in superior output responses with much smaller settling times and less oscillatory behavior in response to disturbances in the electric load than those observed with the FY16 model. Simulation results involving several case studies show that the suggested control scheme could maintain the controlled variables (including the steam utilization factor, cathode stream inlet composition, and temperatures and pressures of the process streams at various locations) within desired limits under various plant operating conditions. The results also indicate that the proposed HTSE plant could provide operational flexibility to participate in energy management at the utility scale by dynamically optimizing the use of excess plant capacity within an N-R HES.

08 HYDROGEN↗

DOE OSTI2017

X-Ray Studies of Delphi Diesel Injection Systems

This CRADA explored the performance of two different models of Delphi diesel injectors. For each injector, the valve needle motion was imaged from two lines of sight at three different injection pressures to characterize its 3D motion. The needle lift was quite repeatable, and followed the expected trend of faster lift with higher injection pressure. In addition, it was observed that the maximum lift increased with injection pressure, even after the valve reached its mechanical limit, indicating that the increased fuel pressure was causing compression or bending of the needle. The off-axis motion of the needle was found to be significant in both measurement planes, though it was very repeatable from one injection event to the next. The effect of ambient pressure on the needle motion was explored at an injection pressure of 400 bar, with ambient pressure up to 15 bar. No effect of the elevated ambient pressure on the needle lift was observed. High-speed x-ray imaging of the spray as it first emerges from the injector nozzle was performed in order to characterize the near-nozzle morphology and breakup of the spray. While imaging was successful at low ambient pressure, the contrast of the images was reduced at high ambient pressures, and quantitative measurements of the morphology were precluded. The near-nozzle fuel distributions were measured using time-resolved x-ray radiography for three injection pressures at an ambient pressure of 33 bar. Increasing injection pressure caused the fuel distribution to narrow, as measured by the Full Width at Half Maximum of the mass distributions. The fuel distributions were quantified for the two injectors at each measurement condition, quantifying the impact that each experimental parameter has on the near-nozzle fuel and air mixture preparation.

42 ENGINEERING↗

DOE OSTI2017

Implementation of Design Changes Towards a More Reliable, Hands-off Magnetron Ion Source [Slides]

As the main H- ion source for the accelerator complex, magnetron ion sources have been used at Fermilab since the 1970’s. At the offline test stand, new R&D is carried out to develop and upgrade the present magnetron-type sources of H- ions of up to 80 mA and 35 keV beam energy in the context of the Proton Improvement Plan. The aim of this plan is to provide high-power proton beams for the experiments at FNAL. In order to reduce the amount of tuning and monitoring of these ion sources, a new electronic system consisting of a current-regulated arc discharge modulator allow the ion source to run at a constant arc current for improved beam output and operation. A solenoid-type gas valve feeds H2 gas into the source precisely and independently of ambient temperature. This summary will cover several studies and design changes that have been tested and will eventually be implemented on the operational magnetron sources at Fermilab. Innovative results for this type of io n source include cathode geometries, solenoid gas valves, current controlled arc pulser, cesium boiler redesign, gas mixtures of hydrogen and nitrogen, and duty factor reduction, with the aim to improve source lifetime, stability, and reducing the amount of tuning needed. In this summary, I will highlight the advances made in ion sources at Fermilab and will outline the directions of the continuing R&D effort.

43 PARTICLE ACCELERATORS↗

DOE OSTI2018

Integrated Component-Specific Measurements to Develop Emission Factors for Compressors and Gas Gathering Lines

The Department of Energy (DOE) National Energy Technology Laboratory (NETL) and other critical stakeholders (e.g., U.S. Environmental Protection Agency (USEPA), state regulators, and industry) seek to more accurately characterize and quantify methane emissions from compressors and gathering lines within the Gathering and Boosting (G&B) segment of the natural gas system network. These efforts will reduce uncertainties in emissions estimates in USEPA’s current Green House Gas Inventory (GHGI) under their Greenhouse Gas Reporting Program (GHGRP). For this study, four G&B stations in the Gulf Coast Area were visited four times over the course of one year. Components were classified according to equipment and component type and emissions from select components were measured using multiple measurement technologies. The following major equipment types were considered: i) compressors, ii) separators, iii) dehydrators, iv) coalescers, v) slug catchers, vi) yard piping, vii) tanks, and viii) gathering lines. Individual components on each equipment type were further divided into the following main categories: i) connectors, ii) valves, iii) pressure relief valves (PRV), iv) meters, v) gauges, vi) regulators, vii) pneumatic device vents, and viii) compressor vents (e.g., distance piece vents [DPVs] and rod packing vents [RPVs]). Components were screened for the presence of leaks and venting emissions with an optical gas imaging (OGI) camera, and methane emission rates were measured using a microdilution high volume sampler. Downwind emissions were measured using an Open Path Fourier Transform Infrared (OP-FTIR) Spectrometer. Data were evaluated to assess correlation with site, equipment, time, and operational variables. Key findings and recommendations from the study include: A) Different counting methodologies can result in vastly different component counts, thus influencing total emissions calculations using Subpart W population EFs. A standard methodology should be adopted for classifying and counting components in order to minimize inconsistencies across studies and instruct stakeholders responsible for GHGI reporting. B) Results support current component subcategories listed in USEPA Subpart W, including the subdivision of connectors (flanged and “other”) and pneumatic device vents (intermittent, continuous low bleed, and continuous high bleed). C) Emission rates vary across sites and a relationship between higher emissions and compressor age was observed for some components. D) Component emission rates varied between field campaigns. The type of components contributing to overall measured emissions also varied among field campaigns. However, the emission rate variability was larger between different components (of the same category) than the variability in one component over the four field campaigns. Therefore, when calculating emission factors, it is not necessary to take repeat measurements to capture component variability. E) Measuring the emission rate of a sample for an extended period of time is not necessary to capture the average component emission rate. F) For reporting purposes, excluding liquid lines from site-wide screening may have a negligible effect on component-related emissions. However, from a site management perspective, malfunctioning components were not uncommon on liquid lines and contributed substantially to fugitive emissions at some sites. G) Population EFs, whether including or excluding liquid lines, were a conservative estimate of fugitive emissions. Leaker EFs consistently underestimated emissions at the field sites. Measurements at more sites, particularity sites in other areas of the country, need to be completed before determining the accuracy of EFs.

03 NATURAL GAS↗

DOE OSTI2018

High Temperature 300°C Measurement While Drilling System

Many countries around the world, including the USA, have untapped geothermal energy potential. Enhanced Geothermal Systems (EGS) technology is needed to economically utilize this resource. Temperatures in some EGS reservoirs can exceed 300°C. To effectively utilize EGS resources, an array of injection and production wells must be accurately placed in the formation fracture network. Therefore, EGS can greatly benefit from a high temperature directional drilling system. Most commercial services for directional drilling systems are rated for 175°C while geothermal wells require operation at much higher temperatures. Two U.S. Department of Energy (DOE) Geothermal Technologies Office (GTO) projects have been initiated to develop a 300°C capable directional drilling system, the first developing a drill bit, directional motor, and drilling fluid (award number DE-EE0002782), and the second adding navigation and telemetry systems. This report is for the second project, “High Temperature 300°C Measurement While Drilling System”, award number DE-EE0005505. The “High Temperature 300°C Measurement While Drilling (MWD)” system complements the already developed drilling system with real time navigation capability. It is comprised of 175°C directional measurement electronics including the required sensors for measuring inclination and azimuth in 3 axes. It is embedded in a cooling and temperature isolation system to protect the electronics and sensors from the higher temperature outside the system, which can reach 300°C. Building the cooling and isolation system from non-magnetic materials and keeping a required distance to any magnetic component, such as alternator parts, ensures a high quality measurement of the earth’s magnetic field. This is required to achieve the specified navigation accuracy. The MWD system has a turbine driven alternator that is capable of delivering the required electrical energy to the electronic system at a 300°C borehole temperature. Measured data will be communicated to the surface by mud-pulse-telemetry. For this purpose the tool has a mud-pulse-valve that is controlled by the measurement electronics to establish a serial data communication via the mud stream. The mud-pulse-valve is also built to operate under 300°C borehole conditions. Three prototypes of the 300°C MWD were built and tested. These systems are available for a joint application with the previously developed 300°C drilling system, in a geothermal well.

15 GEOTHERMAL ENERGY↗

DOE OSTI2019

Pressure Safety Data Package for Remote Balloon Launcher (RBL)

The Barrow Hydrogen Fill System is intended for use by the authorized Sandia National Laboratories personnel and its contractors who are involved in research relating to the deployment of weather balloons for the Department of Energy's Atmospheric Radiation Measurement Program (ARM) https://www.arm.gov/ and The National Weather Service (NWS) https://www.weather.gov/. Hydrogen is supplied from a hydrogen generation shelter and outdoor storage tank. The balloons are filled and released by a remote balloon launcher (RBL) commercially available from Vaisala. The RBL was designed to be used with helium or hydrogen and has be recently inspected by Vaisala for hydrogen operation. This system is composed of a pressure regulator, ball valves, pressure relief valves, tubing, hose. All pressurized components are "off the shelf items and have a minimum pressure rating of 300 psi and are assembled using "Best Practices" and trained pressure component installers. Non pressurized components are comprised of industry recommended components and are assembled using "Best Practices" techniques.

42 ENGINEERING↗

DOE OSTI2020

Development of the INL Thermal Energy Distribution System (TEDS) in the Modelica Eco-System for Validation and Verification

This report provides an overview on the development of the Thermal Energy Distribution System (TEDS) in the Modelica process model eco-system at Idaho National Laboratory as part of the integrated energy system initiative. Model development has led to the creation of a dynamic process model of the experimental TEDS facility housed within the Engineering Science Laboratory (ESL) at INL. The model was then used during the pre-construction phase of the experimental effort to inform experimental design (insulation requirements, bypass line placement, expected performance of components) and to test innovative control schemes prior to the initial operation. The TEDS model developed in Modelica includes the primary components of the TEDS experimental unit including: a 200kW Chromalox heater, a single-tank packed bed thermal energy storage system filled with 0.125 inch Alumina (Al 2 O 3 ), an ethylene-glycol to Therminol-66 heat exchanger, system piping, six control valves, and all associated temperature, pressure, and mass flow sensors. The model does not include nitrogen fill gas tanks, or associated overfill tanks, as these are not part of standard system control. Two simulation sets were run. The first is a five-hour test that operates as a shakedown test for the facility. This simulation puts the facility through all five potential operating modes and showcases the ability of valving, control sensors, and component controllers to meet the system demands. The second case imposes a typical summer day demand on the system from a region with mixed commercial and residential electrical needs where the generator alone cannot meet peak demand but instead requires the thermal storage unit to act as a peaking unit. Over the course of the fifteen-hour discharge cycle heat losses account for a heat loss of approximately 15°C in outlet temperature. Such heat losses would lead to a decrease in overall system efficiency and may lead to additional design changes for such designs in the future that may include a topping heater. Through commencement of this work, a systems level model of TEDS with associated control systems, sensors, piping diameters, and component capabilities has been created. This model has been utilized in the pre-experimental phase to inform system design, insulation thicknesses, and potential control schemes to operate the system effectively and safely. Once TEDS begins operation, this model will be refined, tuned, and used for validation and verification purposes.

24 POWER TRANSMISSION AND DISTRIBUTION↗