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DOE OSTI2025

MPEX AI Digital Twins

All magnetically confined plasma fusion power plant concepts (Tokamak, Spherical Tokamak, Stellarator, Mirror, ...) must exhaust the heat and plasma from the core confinement region to the material walls. The primary channel for this exhaust is through a plasma divertor which directs plasma along open magnetic field lines to a material target. The Material Plasma Exposure eXperiment (MPEX) illustrated in Figure 1, is a high-power, steady-state linear plasma device designed to produce the plasma material interaction (PMI) conditions of the divertor of future magnetic confinement fusion power plants: energy flux 20MW/m 2 , ion fluence 1031/m 2 , pulse duration 106 sec. These goals of plasma exposure in MPEX are well beyond those achieved in magnetic fusion experimental devices. Successfully achieving these high power steady state conditions for long pulses requires operational control of the heating and particle sources and the plasma flux to the walls and target. The MPEX AI Hot Spot Controller, proposed in this project, will help achieve the operational milestones of MPEX. The MPEX device will begin commissioning at the end of FY26. A smaller proto-MPEX was operated for 14,666 plasma discharges and will resume operation in September of 2025 as proto-MPEX-lite, with reduced capability, to test a new window for the Helicon plasma source. The proto-MPEX data has undergone surrogate modeling with machine learning methods (R. Archibald, 2022 IEEE International Conference on Big Data). This proto-MPEX data will be used to begin development of the AI digital twins described in this white paper. The scientific mission of MPEX is to qualify materials of different composition for use in the high energy and plasma flux conditions of a fusion power plant. The materials exposed in MPEX will in some cases be exposed to high neutron fluxes at other ORNL facilities to measure the changes to their PMI properties. The targets exposed in MPEX will be transported under vacuum to a Surface Analysis Station (SAS). The SAS will be equipped with the following diagnostics: Focused Ion Beam (FIB) for trench milling, 100-400 angstrom resolution scanning electron microscope (SEM), surface mapping x-ray spectrometer, high resolution camera, and a future upgrade to a laser induced breakdown spectroscopy quadruple mass spectrometer (LIBS-QMS). The MPEX experiments will generate diverse pre- and post-exposure measurement data of detailed material properties down to the crystal grain level in 3D for post-exposure assessment of PMI damage (e.g. cracking, melting, erosion and redeposition of the material). Physics models for the PMI, and how the material composition and manufacturing impact its performance under high energy plasma exposure, need to be validated with MPEX data to guide the selection of new candidate materials. Our vision for the MPEX AI Digital Twins project is to supply experimental and physics model simulation data to train Artificial Intelligence (AI) models for data processing, analysis, operational control, PMI and materials simulation to maximize the scientific output of the MPEX device. Ultimately, an AI digital twin of MPEX material assessment metrics for tested and synthetic material types with simulated PMI will be trained by the AI Modeling Teams on the experimental and physics simulation data submitted to the American Science Cloud by this project. A purely empirical search for the best material is inefficient given the finite number of samples that can be tested on MPEX. In order to expand the material properties database for training the MPEX Material Assessment AI Digital Twin, and to gain physics understanding of the PMI processes, physics models of the material properties and PMI processes are required. The physics simulations provide detailed simulation data, like impact angles for plasma ions, sputtering yields, transport of the ionized sputtered target material in the plasma, and redeposition locations. This simulation data expands the measurement data for deeper physics understanding. The experimental data is essential to validate the PMI and material structure simulation models. The validated models can then be used to generate new simulation data of MPEX material assessments for synthetic material compositions that have not been exposed in MPEX. These predictive simulations, plus the whole experimental dataset, will be used to train the MPEX Material Assessment AI Digital Twin allowing a rapid generative AI search for new materials with reduced PMI damage by interpolating the domain of the training set. These new optimum materials can be simulated with the physics codes and/or tested in MPEX. The ability of AI neural networks to interpolate multi-dimensional parameter spaces and generate virtual data is exploited for a more efficient search for optimum materials. The advent of the Transformational AI Models Consortium (TAIMC) is an opportunity to engage with state of the art private and public AI developers to achieve the goals of the AI digital twins and AI accelerated physics models proposed in this project. Our partners at ORNL from the Advance Scientific Computing Research (ASCR) organization will collaborate in accelerating the integrated plasma material interaction simulation framework. This simulation framework will provide a platform for generating simulation data across a range of physical fidelities, including hybrid methods that produce multi-fidelity results. This data will be leveraged for AI model development, both for generation of surrogates and the automation of simulation campaigns. A part of the research below will include collaborative efforts with the TAIMC to (i) adapt data storage approaches to ensure AI-readiness, (ii) provide a protypical exemplar to inform and exercise constructed workflows, and (iii) generate and share data, using the TAIMC unified AI data standard, for foundational models that will be trained from multiple sources across the DOE complex. We will also collaborate with the TAIMC, as well as the planned AI modeling teams, to develop approaches for reducing the cost of data generation. These include tailored multi-fidelity approaches as well as fine-tuning strategies to augment general, large-scale foundational models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Hardware Specification and Reference Design for the Low-Cost, Interoperable, User-Centric, Supervisory Controller Kit for Small and Medium Size Commercial Buildings

Commercial buildings are responsible for approximately 20 percent of the total United States energy consumption and greenhouse gas emissions. Over 85 percent of these buildings lack building automation systems to manage the various building systems they have. Many of these buildings are small (< 50,000 square feet), underserved, and use rooftop units (RTUs) for heating, ventilation, and air-conditioning needs. Because these buildings lack proper control systems, they have several operational deficiencies that lead to excess energy consumption. Studies have shown that managing the RTU’s heating and cooling setpoints, schedules, setbacks, and optimal start times can result in 20 to 25 percent reduction in electricity consumption in small and medium commercial buildings (SMBs). In addition, improving the demand flexibility of these buildings will result in additional cost savings for the building owner. To address the needs of the SMBs, the Department of Energy’s Building Technologies Office jointly funded Pacific Northwest National Laboratory (PNNL) and Oak Ridge National Laboratory (ORNL) to design, develop, test, and validate a low-cost, interoperable, user-centric, retrofit supervisory controller kit (SC-SMB) that can be used to continuously optimize energy consumption and deliver demand flexibility of SMBs, including all-electric buildings, and provide a means for maximizing decarbonization benefits. The team also includes industry partners Edo and Intellimation. Previously, the team drafted an SC-SMB system specification document (Goodman et al. 2023). This document describes a reference design of a low-cost supervisory control system for SMBs, including the various hardware components, software system, and an example implementation of the reference design. The final release of the reference design is planned for December 2025. Section 2.0 of the report documents the relevant building types that the SC-SMB system is suitable for. Section 3.0 documents the various hardware components, their function, cost, whether they are off-the-shelve, support standard communication, etc., and the software system. An example deployment in a 10,000-sf building with six rooftop units, a hot water heater, solar, and storage is described in Section 4.0. The planned next steps are described in Section 5.0, and references are listed in Section 6.0.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Prime Time for Model-Predictive Control? Assessing the Technical and Market Readiness of Advanced Controls in Buildings

Despite three decades of extensive research and field testing that have consistently validated the benefits of Model Predictive Control (MPC) in building applications, the technology has seen limited market adoption. This paper evaluates the readiness of MPC for widespread deployment, showcases recent demonstrations and field tests across diverse building types, including residential, small commercial, large commercial, and campus settings. Our results demonstrate that MPC can optimize system operations to achieve load shifting, minimize curtailment of on-site generation, and reduce energy costs by up to 80 %, while maintaining or improving occupant comfort. We also show that MPC can effectively control large assets, such as MW-sized thermal storage systems, and respond to dynamic pricing signals. However, achieving scale remains difficult due to labor-intensive workflows, reliance on a “PhD-in-the-loop” for MPC design and maintenance, susceptibility to fragile data infrastructure, and persistent workforce education and acceptance barriers. To bridge this gap, we outline a transition from bespoke, labor intensive prototypes toward streamlined, segment-targeted deployment strategies that leverage model templates, semantic tools, and generative AI. By automating control configuration and reducing engineering effort, these recommendations provide a pathway for transforming successful research demonstrations into scalable, market ready solutions for MPC-based controls.

Pritoni, Marco↗
DOE OSTI2021

Monitoring leaf phenology in moist tropical forests by applying a superpixel-based deep learning method to time-series images of tree canopies

Tropical leaf phenology-particularly its variability at the tree-crown scale-dominates the seasonality of carbon and water fluxes. However, given enormous species diversity, accurate means of monitoring leaf phenology in tropical forests is still lacking. Time series of the Green Chromatic Coordinate (GCC) metric derived from tower-based red-green-blue (RGB) phenocams have been widely used to monitor leaf phenology in temperate forests, but its application in the tropics remains problematic. To improve monitoring of tropical phenology, we explored the use of a deep learning model (i.e. superpixel-based Residual Networks 50, SP-ResNet50) to automatically differentiate leaves from non-leaves in phenocam images and to derive leaf fraction at the tree-crown scale. To evaluate our model, we used a year of data from six phenocams in two contrasting forests in Panama. Here, we first built a comprehensive library of leaf and non-leaf pixels across various acquisition times, exposure conditions and specific phenocams. We then divided this library into training and testing components. We evaluated the model at three levels: 1) superpixel level with a testing set, 2) crown level by comparing the model-derived leaf fractions with those derived using image-specific supervised classification, and 3) temporally using all daily images to assess the diurnal stability of the model-derived leaf fraction. Finally, we compared the model-derived leaf fraction phenology with leaf phenology derived from GCC. Our results show that: 1) the SP-ResNet50 model accurately differentiates leaves from non-leaves (overall accuracy of 93%) and is robust across all three levels of evaluations; 2) the model accurately quantifies leaf fraction phenology across tree-crowns and forest ecosystems; and 3) the combined use of leaf fraction and GCC helps infer the timing of leaf emergence, maturation and senescence, critical information for modeling photosynthetic seasonality of tropical forests. Collectively, this study offers an improved means for automated tropical phenology monitoring using phenocams.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Smart distribution systems

The increasing importance of system reliability and resilience is changing the way distribution systems are planned and operated. To achieve a distribution system self-healing against power outages, emerging technologies and devices, such as remote-controlled switches (RCSs) and smart meters, are being deployed. The higher level of automation is transforming traditional distribution systems into the smart distribution systems (SDSs) of the future. The availability of data and remote control capability in SDSs provides distribution operators with an opportunity to optimize system operation and control. In this paper, the development of SDSs and resulting benefits of enhanced system capabilities are discussed. A comprehensive survey is conducted on the state-of-the-art applications of RCSs and smart meters in SDSs. Specifically, a new method, called Temporal Causal Diagram (TCD), is used to incorporate outage notifications from smart meters for enhanced outage management. To fully utilize the fast operation of RCSs, the spanning tree search algorithm is used to develop service restoration strategies. Optimal placement of RCSs and the resulting enhancement of system reliability are discussed. Distribution system resilience with respect to extreme events is presented. Furthermore, test cases are used to demonstrate the benefit of SDSs. Active management of distributed generators (DGs) is introduced. Future research in a smart distribution environment is proposed.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Comparison of Machine Learning and Deep Learning for View Identification from Cardiac Magnetic Resonance Images

Background: Artificial intelligence is increasingly utilized to aid in the interpretation of cardiac magnetic resonance (CMR) studies. One of the first steps is the identification of the imaging plane depicted, which can be achieved by both deep learning (DL) and classical machine learning (ML) techniques without user input. We aimed to compare the accuracy of ML and DL for CMR view classification and to identify potential pitfalls during training and testing of the algorithms. Methods: To train our DL and ML algorithms, we first established datasets by retrospectively selecting 200 CMR cases. The models were trained using two different cohorts (passively and actively curated) and applied data augmentation to enhance training. Once trained, the models were validated on an external dataset, consisting of 20 cases acquired at another center. We then compared accuracy metrics and applied class activation mapping (CAM) to visualize DL model performance. Results: The DL and ML models trained with the passively-curated CMR cohort were 99.1% and 99.3% accurate on the validation set, respectively. However, when tested on the CMR cases with complex anatomy, both models performed poorly. After training and testing our models again on all 200 cases (active cohort), validation on the external dataset resulted in 95% and 90% accuracy, respectively. The CAM analysis depicted heat maps that demonstrated the importance of carefully curating the datasets to be used for training. Conclusions: Both DL and ML models can accurately classify CMR images, but DL outperformed ML when classifying images with complex heart anatomy.

artificial intelligence↗
DOE OSTI2020

A scoping review of non-destructive testing (NDT) techniques in building performance diagnostic inspections

Understanding building envelope thermodynamics is an essential foundation of building sciences, mainly due to the envelope’s role as a boundary layer for exterior environments, as well as a container and regulator of internal microclimates. This paper presents a scoping literature review of select Non-destructive Testing (NDT) techniques for building envelope scanning and surveying for thermodynamic diagnostics. The investigation focuses specifically on reviewing six NDT techniques: Ground Penetrating Radar (GPR), Light Detection and Ranging (LiDAR)/Laser Scanning, Thermography, Ultrasound, Close-Range Photogrammetry and Through Wall Imaging Radar (TWIR). The aim is to identify knowledge gaps in terms of their use in accurately characterizing envelope compositions for further integration in Building Energy Modeling (BEM). Each technique was evaluated according to set categories imbibed from the American Society of Heating, Refrigerating, and Air Conditioning Engineering (ASHRAE) Standard 211P that showcase the technique’s ability to extract various relevant information. A framework is then developed to inform users on how to use hybrid NDT-based workflows applied in building envelope energy audits. The study concludes by discussing possibilities of utilizing NDT in large-scale audit automation, BEM integration, and developing built environment policies focusing on increasing existing building performance through retrofitting design.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sensor cost-effectiveness analysis for data-driven fault detection and diagnostics in commercial buildings

Data-driven building fault detection and diagnostics (FDD) is heavily dependent on sensors. However, common sensors from Building Automation Systems are not optimized to maximize accuracy in FDD. Installing additional sensors that provide more detailed building system information is key to maximizing the performance of FDD solutions. Here in this paper, we present a sensor cost analysis workflow to quantify the economic implications of installing new sensors for FDD using the concept of sensor threshold marginal cost (STMC). STMC does not represent actual sensor cost. Rather, it represents a target cost based on the economic benefit that would be realized through improved FDD performance and one or more specified economic criteria. We calculate STMCs for multiple possible fault types and use fault prevalence information to aggregate STMCs into a single dollar value to determine the cost-effectiveness of a potential sensor investment. We conducted a case study using Oak Ridge National Laboratory's Flexible Research Platform (FRP) test facility as a reference. The case study demonstrates the feasibility of the analysis and highlights the key cost considerations in sensor selection for FDD. The results also indicate that identifying and installing the few key sensor(s) is critical to cost-effectively improve FDD performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Novel platinum group metal-free catalyst ink deposition system for combinatorial polymer electrolyte fuel cell performance evaluation

Here, a new system for rapid and precise fabrication of polymer electrolyte fuel cell (PEFC) membrane-electrode assemblies (MEAs) is introduced to facilitate rapid testing and characterization of platinum group metal-free (PGM-free) catalysts, with minimal waste of materials, using commercial combinatorial hardware and multi-channel potentiostat. The commercial combinatorial system, designed for high-throughput catalyst activity evaluation (i.e., low overpotential and current densities) using gas-diffusion electrodes (GDEs), has been further developed to enable simultaneous evaluation of the high current density performance on air of twenty-five cathodes prepared by coating catalyst-ionomer inks directly onto the membrane using a newly-developed deposition system. A nanopipette or micropipette coupled to a precise peristaltic pump is being used for precise and even catalyst ink deposition onto the membrane in each of twenty-five circular electrodes with areas of <1 cm 2 and in the precise locations required by the commercial combinatorial MEA hardware. The automated ink deposition system is coupled with a custom-designed heated vacuum table mounted on a computer-controlled XY stage to prevent deformation of the membrane and electrode layers during ink deposition onto the membrane. This system was utilized to evaluate the impact of ionomer to catalyst ratio on the hydrogen-air fuel cell performance of the PGM-free catalyst.

25 ENERGY STORAGE↗
DOE OSTI2024

A Large-Scale Analysis to Optimize the Control and V2V Communication Protocols for CDA Agreement-Seeking Cooperation

Cooperative driving automation (CDA) Class C, agreement-seeking cooperation, is an innovative and practical solution that can promote cooperation among general passenger vehicles on the road. However, more comprehensive studies are needed before establishing the standard protocols of agreement-seeking cooperation, such as communication frequency and the duration of cooperation. Here, this article presents an initiative study on the impacts of communication capabilities on agreement-seeking cooperation. Through a large-scale analysis by regulating vehicle-to-vehicle (V2V) communication metrics, this work suggests desirable system parameters that can maximize the benefits of cooperation and ensure reliable operability while avoiding exhaustive communication loads. As the first step, an example agreement-seeking cooperation system is created for a car-following scenario, including decision-making and control algorithms for autonomous vehicles. Then, software-in-the-loop tests explore the performance of the developed system as it encounters various communication risks, such as latency and message packet drops. The system performance metrics are evaluated from various angles, including the time consumed for the agreement-seeking process, cooperation ratio, and the ratio of faulty cooperation. Energy saving from the cooperation is assessed by using simulation software that can run multiple high-fidelity vehicle models simultaneously. Based on the analyses, this article suggests the V2V communication requirements for the reliable operation of CDA agreement-seeking, which can be referred to when developing the standard protocols of agreement-seeking cooperation.

42 ENGINEERING↗
DOE OSTI2014

Analysis of Open Automated Demand Response Deployments in California and Guidelines to Transition to Industry Standards

This report reviews the Open Automated Demand Response (OpenADR) deployments within the territories serviced by California's investor-owned utilities (IOUs) and the transition from the OpenADR 1.0 specification to the formal standard?OpenADR 2.0. As demand response service providers and customers start adopting OpenADR 2.0, it is necessary to ensure that the existing Automated Demand Response (AutoDR) infrastructure investment continues to be useful and takes advantage of the formal standard and its many benefits. This study focused on OpenADR deployments and systems used by the California IOUs and included a summary of the OpenADR deployment from the U.S. Department of Energy-funded demonstration conducted by the Sacramento Municipal Utility District (SMUD). Lawrence Berkeley National Laboratory collected and analyzed data about OpenADR 1.0 deployments, categorized architectures, developed a data model mapping to understand the technical compatibility of each version, and compared the capabilities and features of the two specifications. The findings, for the first time, provided evidence of the total enabled load shed and average first cost for system enablement in the IOU and SMUD service territories. The OpenADR 2.0a profile specification semantically supports AutoDR system architectures and data propagation with a testing and certification program that promotes interoperability, scaled deployments by multiple vendors, and provides additional features that support future services.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

PHOTOMETRIC SUPERNOVA CLASSIFICATION WITH MACHINE LEARNING

Automated photometric supernova classification has become an active area of research in recent years in light of current and upcoming imaging surveys such as the Dark Energy Survey (DES) and the Large Synoptic Survey Telescope, given that spectroscopic confirmation of type for all supernovae discovered will be impossible. Here, we develop a multi-faceted classification pipeline, combining existing and new approaches. Our pipeline consists of two stages: extracting descriptive features from the light curves and classification using a machine learning algorithm. Our feature extraction methods vary from model-dependent techniques, namely SALT2 fits, to more independent techniques that fit parametric models to curves, to a completely model-independent wavelet approach. We cover a range of representative machine learning algorithms, including naive Bayes, k -nearest neighbors, support vector machines, artificial neural networks, and boosted decision trees (BDTs). We test the pipeline on simulated multi-band DES light curves from the Supernova Photometric Classification Challenge. Using the commonly used area under the curve (AUC) of the Receiver Operating Characteristic as a metric, we find that the SALT2 fits and the wavelet approach, with the BDTs algorithm, each achieve an AUC of 0.98, where 1 represents perfect classification. We find that a representative training set is essential for good classification, whatever the feature set or algorithm, with implications for spectroscopic follow-up. Importantly, we find that by using either the SALT2 or the wavelet feature sets with a BDT algorithm, accurate classification is possible purely from light curve data, without the need for any redshift information.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2015

Highly Automated Module Production Incorporating Advanced Light Management

The objective was to enable a high volume, cost effective solution for increasing the amount of light captured by PV modules through utilization of an advanced Light Re-directing Film and to follow a phased approach to develop and implement this new technology in order to achieve an expected power gain of up to 12 watts per module. Full size PV modules were manufactured using a new Light Redirecting Film (LRF) material applied to two different areas of PV modules in order to increase the amount of light captured by the modules. One configuration involved applying thin strips of LRF film over the tabbing ribbon on the cells in order to redirect the light that is normally absorbed by the tabbing ribbon to the active areas of the cells. A second configuration involved applying thin strips of LRF film over the white spaces between cells within a module in order to capture some of the light that is normally reflected from the white areas back through the front glass of the modules. Significant power increases of 1.4% (3.9 watts) and 1.0% (3.2 watts), respectively, compared to standard PV modules were measured under standard test conditions. The performance of PV modules with LRF applied to the tabbing ribbon was modeled. The results showed that the power increase provided by LRF depended greatly on the angle of incident light with the optimum performance only occurring when the light was within a narrow range of being perpendicular to the solar module. The modeling showed that most of the performance gain would be lost when the angle of incident light was greater than 28 degrees off axis. This effect made the orientation of modules with LRF applied to tabbing ribbons very important as modules mounted in “portrait” mode were predicted to provide little to no power gain from LRF under real world conditions. Based on these results, modules with LRF on tabbing ribbons would have to be mounted in “landscape” mode to realize a performance advantage. In addition, modeling showed that under diffuse lighting conditions such as when the sky is overcast, there would be no significant performance advantage for modules with LRF. Modules were sent to an outside contractor to measure the power performance under different angles of incident light in order to validate the modeling results. The measured data agreed very well with the modeling predictions and showed that the power gain for modules with LRF applied to tabbing ribbons was completely lost at an angle of 25 degrees off of perpendicular. At even larger angles, the power was lower than standard modules. From 35 degrees to 55 degrees off axis, the power loss was about 1.4% or equal to the power gain at the optimum condition of perfectly on-axis light.

14 SOLAR ENERGY↗
DOE OSTI2021

Performance demonstration of vacuum microwave components critical for the operation of the ITER low-field side reflectometer

Final design studies in preparation for manufacturing have been performed for functional components of the vacuum portion of the ITER Low-Field Side Reflectometer (LFSR). These components consist of an antenna array, electron cyclotron heating (ECH) protection mirrors, phase calibration mirrors, and vacuum windows. Evaluation of these components was conducted at the LFSR test facility and DIII-D. The antenna array consists of six corrugated-waveguide antennas for simultaneous profile, fluctuation, and Doppler measurements. A diffraction grating, incorporated into the plasma-facing miter bend, provides protection of sensitive components from stray ECH at 170 GHz. For in situ phase calibration of the LFSR profile reflectometer, an embossed mirror is incorporated into the adjacent miter bend. Measurements of the radiated beam profile indicate that these components have a small, acceptable effect on mode conversion and beam quality. Baseline transmission characteristics of the dual-disk vacuum window are obtained and are used to guide ongoing developments. Preliminary simulations indicate that a surface-relief structure on the window surfaces can greatly improve transmission. The workability of real-time phase measurements was demonstrated on the DIII-D profile reflectometer. The new automated real-time analysis agrees well with the standard post-processing routine.

47 OTHER INSTRUMENTATION↗
DOE OSTI2012

PDC IC Weld Failure Evaluation and Resolution

During final preparations for start of the PDCF Inner Can (IC) qualification effort, welding was performed on an automated weld system known as the PICN. During the initial weld, using a pedigree canister and plug, a weld defect was observed. The defect resulted in a hole in the sidewall of the canister, and it was observed that the plug sidewall had not been consumed. This was a new type of failure not seen during development and production of legacy Bagless Transfer Cans (FB-Line/Hanford). Therefore, a team was assembled to determine the root cause and to determine if the process could be improved. After several brain storming sessions (MS and T, R and D Engineering, PDC Project), an evaluation matrix was established to direct this effort. The matrix identified numerous activities that could be taken and then prioritized those activities. This effort was limited by both time and resources (the number of canisters and plugs available for testing was limited). A discovery process was initiated to evaluate the Vendor's IC fabrication process relative to legacy processes. There were no significant findings, however, some information regarding forging/anneal processes could not be obtained. Evaluations were conducted to compare mechanical properties of the PDC canisters relative to the legacy canisters. Some differences were identified, but mechanical properties were determined to be consistent with legacy materials. A number of process changes were also evaluated. A heat treatment procedure was established that could reduce the magnetic characteristics to levels similar to the legacy materials. An in-situ arc annealing process was developed that resulted in improved weld characteristics for test articles. Also several tack welds configurations were addressed, it was found that increasing the number of tack welds (and changing the sequence) resulted in decreased can to plug gaps and a more stable weld for test articles. Incorporating all of the process improvements for the actual can welding process, however, did not result in an improved weld geometry. Several possibilities for the lack of positive response exist, some of which are that (1) an insufficient number of test articles were welded under prototypic conditions, (2) the process was not optimized so that significant improvements were observable over the "noise", and (3) the in-situ arc anneal closed the gap down too much so the can was unable to exhaust pressure ahead of the weld. Several operational and mechanical improvements were identified. The weld clamps were changed to a design consistent with those used in the legacy operations. A helium puff operation was eliminated; it is believed that this operation was the cause of the original weld defect. Also, timing of plug mast movement was found to correspond with weld irregularities. The timing of the movement was changed to occur during weld head travel between tacks. In the end a three sequential tack weld process followed by a pulse weld at the same current and travel speed as was used for the legacy processes was suggested for use during the IC qualification effort. Relative to legacy welds, the PDC IC weld demonstrates greater fluctuation in the region of the weld located between tack welds. However, canister weld response (canister to canister) is consistent and with the aid of the optical mapping system (for targeting the cut position) is considered adequate. DR measurements and METs show the PDC IC welds to have sufficient ligament length to ensure adequate canister pressure/impact capacity and to ensure adequate stub function. The PDC welding process has not been optimized as a result of this effort. Differences remain between the legacy BTC welds and the PDC IC weld, but these differences are not sufficient to prevent resumption of the current PDC IC qualification effort. During the PDC IC qualification effort, a total of 17 cans will be welded and a variety of tests/inspections will be performed. The extensive data collected during that qualification effort should be of a sufficient population to determine if additional weld process optimization is necessary prior to production release.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

NRC technical basis for evaluation of its position on protection against common cause failure in digital systems used in nuclear power plants - 378

Digital technology has advantages over analog systems, including automated monitoring and alerts for standby safety functions, and predictive algorithms to maintain critical safety systems. Additionally, digital technology generally has higher reliability and can be designed to reduce single point vulnerabilities. For these reasons many nuclear plants have applied digital technology to safety and non-safety related applications, including reactor protection system, feedwater and turbine controls, etc. with a corresponding significant improvement in trip reduction. Nonetheless, digital instrumentation and control (I and C) systems also present potential new vulnerabilities that need to be assessed, including potential failures due to increased complexity of digital systems, the introduction of unique failure modes due to software (including software common cause failure (CCF)), and limited operating history of digital systems in nuclear safety related applications compared to analog systems. The fact that software is intangible means that common methods, such as analysis or testing, used for detecting CCF may not be effective when applied to software. Consequently, digital technology is perceived to pose a potential risk from the introduction of undetected systematic faults that could result in CCF. Despite the I and C system upgrades and modifications performed to date, the U.S. Nuclear Regulatory Commission (NRC) and industry stakeholders have identified the need to modernize the regulatory infrastructure to efficiently address risks associated with the use of digital technology for nuclear safety applications and address regulatory uncertainties. The NRC's current position on CCF is guided by the staff requirements memorandum (SRM) on SECY 93-087. The SRM provides specific acceptance criteria for the evaluation of CCF, which the staff implemented in the Branch Technical Position (BTP) 7-19. However, industry stakeholders have proposed using methods to characterize the likelihood of software CCF and eliminate it from further consideration in a defense-in-depth and diversity analysis. The NRC's current position does not consider these alternatives, and thus corresponding acceptance criteria is not currently available. The work discussed in this paper assesses the underlying technical basis associated with CCF, provides technical support for updating the NRC position and considers proposed methods for addressing potential CCF in digital systems while enhancing efficiency, clarity, and confidence. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Performance Assessment of a New Gamma Spectroscopy Toolkit: Peak Doctor and the Spectral Nondestructive Assay Platform (SNAP) - 17397

High resolution gamma spectroscopy (HRGS) is a widely used technique for non-destructive characterization of nuclear materials, and assay of radioactive waste. The ability to accurately evaluate raw spectral data is an important step in producing high-quality results. A spectral analysis application known as Peak Doctor has been developed under a Cooperative Research and Development Agreement (CRADA) between LANL and Pajarito Scientific Corporation (PSC). The software has undergone several years of testing and validation by the Radioactive Waste Characterization Team of the LANL Waste Management Services Group (WM-SVS). PeakDoctor is designed to work with the Spectral Nondestructive Assay Platform (SNAP{sup TM}) to provide a complete HRGS analysis engine. SNAP{sup TM} performs model specific corrections for attenuation and geometry. These applications are the major components of a new toolkit designed primarily for portable far-field non-destructive assay. Peak Doctor performs a very accurate peak fit analysis with the goal of improving upon the capabilities of existing commercially available routines. It is designed to be user-configurable and can be customized to any given type of detector and any given type of spectrum. Peak Doctor was developed to resolve many of the inherent complexities in gamma ray spectra including overlapping peaks, complex multiplet regions, large step peaks, backscatter regions and Compton edges. Unlike most spectral analysis platforms, Peak Doctor does not rely on the energy calibration and detector resolution parameters that are saved by the operator in the spectrum file. Instead, key parameters are pre-defined for individual detectors. The software fits a continuum using a series of splines between a series of junctions or 'knots'. Fitting techniques are used to join the splines together to create a near-continuous multi-element curve. Optimizing the location of the knots is one of Peak Doctor's most powerful features. The knots are initially configured using a pre-defined list and are removed or added automatically during the fitting process. Knots are also created when new features are identified such as Step Peaks and Compton Edges. The user can also manually specify knots in order to improve the continuum fit. The initial fit is improved on by removing any outlier regions (which are converted to peaks) and the continuum fitting process is repeated. At this stage, an experienced user can work interactively with the fit by manually converting peak regions to continuum or vice versa. The final step is to fit a series of peaks above the continuum based on detector parameters. Single and multiplet peaks are then processed by either the tailing (piecewise) or non-tailing (Gaussian) Levenberg Marquardt non-linear peak fitting routine depending on the user defined selection. Only a rough knowledge of the detector characteristics (energy calibration and resolution) is required for the fitting process to proceed with good accuracy. Any peaks that are missed can be manually added by the user and will also be fitted. Discontinuities in the peak / continuum fit can be rapidly identified by reviewing the 'residuals scale' plot. For waste streams that are well characterized, it is often the case that routinely encountered spectra will have similar peaks and continuum features. For these cases a handy 'One Step' method is available that proceeds in an automated fashion without user interaction. Peak Doctor has been configured with a set of default spectrum types including plutonium / transuranic waste (including Weapons Grade Pu, Heat Source Pu, Am-241, Am-243 and Np-237), depleted or enriched uranium, nuclear power plant / intermediate level waste (with fission and activation products such as Cs-137 and Co-60) as well as Naturally Occurring Radioactive Materials (NORM). The user can easily add new spectrum types for specific waste streams or other types of radiological / special nuclear materials. The output from PeakDoctor (including net peak area, centroid energy and a list of minimum detectable activity levels at pre-defined regions) is used by SNAP{sup TM} to complete the data analysis process. Isotope activities are calculated using configurable template-driven geometry and attenuation correction methods. The software accounts for matrix and container wall effects, collimator / angular corrections, detector efficiency (based on calibration curves) and stand-off distance. SNAP{sup TM} uses published algorithms incorporating a series of decision points during its operation to allow the analyst to provide logical input to guide the software during the analysis of each unique spectrum. The Peak Doctor / SNAP{sup TM} toolkit has been extensively tested and validated under a variety of conditions using 'benchmark' reference spectra. Test scenarios reported include HPGe-based measurements of well characterized uranium and plutonium standards and radioactive sources with a variety of different geometries and matrix materials including surrogate drums and boxes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Fast Megavoltage Computed Tomography: A Rapid Imaging Method for Total Body or Marrow Irradiation in Helical Tomotherapy

Purpose: Megavoltage computed tomographic (MVCT) imaging has been widely used for the 3-dimensional (3-D) setup of patients treated with helical tomotherapy (HT). One drawback of MVCT is its very long imaging time, the result of slow couch speeds of approximately 1 mm/s, which can be difficult for the patient to tolerate. We sought to develop an MVCT imaging method allowing faster couch speeds and to assess its accuracy for image guidance for HT. Methods and Materials: Three cadavers were scanned 4 times with couch speeds of 1, 2, 3, and 4 mm/s. The resulting MVCT images were reconstructed using an iterative reconstruction (IR) algorithm with a penalty term of total variation and with a conventional filtered back projection (FBP) algorithm. The MVCT images were registered with kilovoltage CT images, and the registration errors from the 2 reconstruction algorithms were compared. This fast MVCT imaging was tested in 3 cases of total marrow irradiation as a clinical trial. Results: The 3-D registration errors of the MVCT images reconstructed with the IR algorithm were smaller than the errors of images reconstructed with the FBP algorithm at fast couch speeds (2, 3, 4 mm/s). The scan time and imaging dose at a speed of 4 mm/s were reduced to 30% of those from a conventional coarse mode scan. For the patient imaging, faster MVCT (3 mm/s couch speed) scanning reduced the imaging time and still generated images useful for anatomic registration. Conclusions: Fast MVCT with the IR algorithm is clinically feasible for large 3-D target localization, which may reduce the overall time for the treatment procedure. This technique may also be useful for calculating daily dose distributions or organ motion analyses in HT treatment over a wide area. Automated integration of this imaging is at least needed to further assess its clinical benefits.

62 RADIOLOGY AND NUCLEAR MEDICINE↗