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DOE OSTI2024

Multiphysics Simulations of Thermal Shock Testing of Nanofibrous High Power Targets

Increase of primary beam power for neutrino beam-lines leads to a reduced lifespan for production targets. The field of High Power Targetry (HPT) is generating new concepts to meet the need for robust targets. One idea being investigated by the HPT Research and Development Group at Fermilab is an electrospun nanofiber target. As part of their evaluation, samples with different densities were sent to the HiRadMat facility at CERN for thermal shock tests. The samples with the higher density, irradiated under a high intensity beam pulse, exhibit major damages at the impact site whereas those with the lower density show no apparent damages. The exact cause of this failure was unclear at the time. In this paper, we present the results of multiphysics simulations of the thermal shock experienced by the nanofiber targets that suggest the failure originates from the reduced permeability of the high density sample to airflow. The air present in the porous target expands due to heating from the beam, but is unable to flow freely in the high density sample, resulting in a larger back pressure that blows apart the mat. We close with a discussion on how to further validate this hypothesis.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Deep Learning Based Superconducting Radio-Frequency Cavity Fault Classification at Jefferson Laboratory

This work investigates the efficacy of deep learning (DL) for classifying C100 superconducting radio-frequency (SRF) cavity faults in the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab. CEBAF is a large, high-power continuous wave recirculating linac that utilizes 418 SRF cavities to accelerate electrons up to 12 GeV. Recent upgrades to CEBAF include installation of 11 new cryomodules (88 cavities) equipped with a low-level RF system that records RF time-series data from each cavity at the onset of an RF failure. Typically, subject matter experts (SME) analyze this data to determine the fault type and identify the cavity of origin. This information is subsequently utilized to identify failure trends and to implement corrective measures on the offending cavity. Manual inspection of large-scale, time-series data, generated by frequent system failures is tedious and time consuming, and thereby motivates the use of machine learning (ML) to automate the task. This study extends work on a previously developed system based on traditional ML methods (Tennant and Carpenter and Powers and Shabalina Solopova and Vidyaratne and Iftekharuddin, Phys. Rev. Accel. Beams, 2020, 23, 114601), and investigates the effectiveness of deep learning approaches. The transition to a DL model is driven by the goal of developing a system with sufficiently fast inference that it could be used to predict a fault event and take actionable information before the onset (on the order of a few hundred milliseconds). Because features are learned, rather than explicitly computed, DL offers a potential advantage over traditional ML. Specifically, two seminal DL architecture types are explored: deep recurrent neural networks (RNN) and deep convolutional neural networks (CNN). We provide a detailed analysis on the performance of individual models using an RF waveform dataset built from past operational runs of CEBAF. In particular, the performance of RNN models incorporating long short-term memory (LSTM) are analyzed along with the CNN performance. Furthermore, comparing these DL models with a state-of-the-art fault ML model shows that DL architectures obtain similar performance for cavity identification, do not perform quite as well for fault classification, but provide an advantage in inference speed.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Accelerating Learning with Set-Based Concurrent Engineering

The traditional design approach for product development is to develop a design based on customer requirements and technical knowledge, build the product according to the detail requirements provided, and then test the product to validate that it works as intended. The team typically starts by identifying a single design approach and spends their time validating a single design during testing. Design teams often encounter issues in the course of development with performance, manufacturability, interfaces and more. To compensate for test failures, teams often build in time into the schedule for additional design loopbacks. Further, when the loopbacks lead to change, the late changes are costly and risky, causing the team to focuses on "fixing the bare minimum" to meet cost and schedule expectations.

42 ENGINEERING↗

DOE OSTI2020

Substation Secondary Asset Health Monitoring and Management System (SSHM)

Electric Power Group, LLC (EPG) was awarded DOE OE0000850 to design, develop, and demonstrate a real-time software application for substation secondary equipment health monitoring and management at host utility American Electric Power (AEP), a cost share partner. This project addresses the need for monitoring substation equipment health and providing operators with tools to identify and take pre-emptive action to avoid catastrophic equipment failure. By monitoring synchrophasor data in real time, data anomalies that indicate potential asset failure can be detected and alerts can be sent to operators in time to take corrective actions. EPG developed two data driven algorithms to identify abnormal equipment signature patterns as well as a method using substation linear state estimation (SLSE). The software has been deployed on hardened PC’s and tested and validated for cost share partner AEP’s substations - 138kV and 765 kV. The SSHM software has been accepted by AEP and final demonstration of DOE - OE0000850 for AEP and DOE was successfully completed on March 17th, 2020. EPG developed the Substation Secondary Asset Health Monitoring (SSHM) Platform to analyze equipment failure signatures in PMU data and alert substation personnel when pre-emptive inspection, repairs and other actions are warranted to prevent potential catastrophic failures. This is the first system that automatically monitors the health of substation secondary assets and alerts users to emerging failures using synchrophasor measurements. SSHM uses high resolution PMU data from PTs, CTs, and CCVTs to analyze equipment signatures and identify anomalies that are precursor indicators of potential equipment failure. When an anomaly is detected, there is a likelihood of potential failure of monitored equipment, the system alerts the user with visual alarms including alarm trend charts and indicator lights on a oneline diagram of the substation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Failure diagnosis and trend‐based performance losses routines for the detection and classification of incidents in large‐scale photovoltaic systems

Abstract Fault detection and classification in photovoltaic (PV) systems through real‐time monitoring is a fundamental task that ensures quality of operation and significantly improves the performance and reliability of operating systems. Different statistical and comparative approaches have already been proposed in the literature for fault detection; however, accurate classification of fault and loss incidents based on PV performance time series remains a key challenge. Failure diagnosis and trend‐based performance loss routines were developed in this work for detecting PV underperformance and accurately identifying the different fault types and loss mechanisms. The proposed routines focus mainly on the differentiation of failures (e.g., inverter faults) from irreversible (e.g., degradation) and reversible (e.g., snow and soiling) performance loss factors based on statistical analysis. The proposed routines were benchmarked using historical inverter data obtained from a 1.8 MWp PV power plant. The results demonstrated the effectiveness of the routines for detecting failures and loss mechanisms and the capability of the pipeline for distinguishing underperformance issues using anomaly detection and change‐point (CP) models. Finally, a CP model was used to extract significant changes in time series data, to detect soiling and cleaning events and to estimate both the performance loss and degradation rates of fielded PV systems.

14 SOLAR ENERGY↗

DOE OSTI2020

Enhanced Component Performance Study: Emergency Diesel Generators 1998–2018

This report presents an enhanced performance evaluation of emergency diesel generators (EDGs) at U.S. commercial nuclear power plants. This report evaluates component performance over time using (1) Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES) data from 1998 through 2018 and (2) maintenance unavailability (UA) performance data from Mitigating Systems Performance Index (MSPI) Basis Document data from 2002 through 2018. The objective is to show estimates of current failure probabilities and rates related to EDGs, trend these data on an annual basis, determine if the current data are consistent with the probability distributions currently recommended for use in NRC probabilistic risk assessments, show how the reliability data differ for different EDG manufacturers and for EDGs with different ratings; and summarize the subcomponents, causes, detection methods, and recovery associated with each EDG failure mode. Engineering analyses were performed with respect to time period and failure mode without regard to the actual number of EDGs at each plant. The factors analyzed are: sub-component, failure cause, detection method, recovery, manufacturer, and EDG rating. A statistically significant increasing trend was identified in the frequency of FTLR demands for emergency power system (EPS) and high pressure core spray (HPCS) EDGs and a statistically significant decreasing trend was identified in the frequency of run > 1H hours for EPS and HPCS EDGs.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Metamodels for Rapid Analysis of Large Sets of Building Designs for Robotic Constructability: Technology Demonstration Using the NASA 3D Printed Mars Habitat Challenge

Disruptive robotic construction technologies such as additive deposition of cementitious materials like concrete (or "3D concrete printing") require the synchronous operation of multiple pieces of equipment in the production setup. In such an environment, it is crucial to simulate the robotic motions (for toolpath clashes) and the cementitious material behavior (for toolpath failures) to ensure fail-proof constructability of the envisioned building geometry. However, toolpath clash detection requires 4D simulations of the production setup, which are computationally graphics intensive, whereas toolpath failure detection requires actual 3D printing of test parts from the geometry to identify areas prone to failure while 3D printing, which is physically tedious. Both these processes, being computationally and physically intensive, have largely curtailed designers from simulating and exploring large sets of design options with varying geometries and toolpath configurations. To overcome this and allow designers to explore large sets of design possibilities, this paper proposes two novel computational metamodels capable of performing robotic toolpath clash detection and failure detection with significantly reduced times than the earlier approaches. The developed metamodels were used to rapidly simulate large sets of building design options for robotic constructability in the NASA 3D-Printed Mars Habitat Challenge.

clash detection↗

DOE OSTI2023

Predicting Failure Using Deep Learning SAND Report

Accurate prediction of ductile failure is critical to Sandia’s NW mission, but the models are computationally heavy. The costs of including high-fidelity physics and mechanics that are germane to the failure mechanisms are often too burdensome for analysts either because of the person-hours it requires to input them or because of the additional computational time, or both. In an effort to deliver analysts a tool for representing these phenomena with minimal impact to their existing workflow, our project sought to develop modern data-driven methods that would add microstructural information to business-as-usual calculations and expedite failure predictions. The goal is a tool that receives as input a structural model with stress and strain fields, as well as a machine-learned model, and output predictions of structural response in time, including failure. As such, our project spent substantial time performing high-fidelity, three-dimensional experiments to elucidate materials mechanisms of void nucleation and evolution. We developed crystal-plasticity finite-element models from the experimental observations to enrich the findings with fields not readily measured. We developed engineering length-scale simulations of replicated test specimens to understand how the engineering fields evolve in the presence of fine-scale defects. Finally, we developed deep learning convolutional neural networks, and graph-based neural networks to encode the findings of the experiments and simulations and make forward predictions in time for structural performance. This project demonstrated the power of data-driven methods for model development, which have the potential to vastly increase both the accuracy and speed of failure predictions. These benefits and the methods necessary to develop them are highlighted in this report. However, many challenges remain to implementing these in real applications, and these are discussed along with potential methods for overcoming them.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Blockchain for Fault-Tolerant Grid Operations Version 2.0

This report explores the potential of distributed ledger technology (DLT) as a transformative tool to enhance fault-tolerant operations in electrical distribution systems. Leveraging DLT's core attributes, including an immutable decentralized ledger, distributed consensus mechanisms, and state replication capabilities, this study focuses on three critical use cases. A central aspect of this research centers on the utilization of a consensus-driven ledger, providing actors within the system, such as distributed resources, with access to a reliable data repository. This empowers these actors to collaborate effectively and make informed decisions, all securely recorded on the blockchain. The first use case concentrates on data configuration, utilizing mathematical criteria---particularly, the chi-squared test for gross error detection---to identify trustworthy sensors for advanced decision-making. Building upon this foundation of trust, the second use case, topology identification, accurately determines circuit breaker states, unveiling the distribution network's topology. Ultimately, the third use case leverages this trust to execute switching actions, reconfiguring feeders and restoring power to disconnected customers after fault events. The concept of trust serves as a cornerstone in this approach, marking a departure from traditional fault location, isolation, and service restoration (FLISR) methods. Additionally, the blockchain-based architecture introduces decentralization, empowering disconnected areas to make autonomous decisions, even when communication with a central control center is disrupted. The primary contributions of this report are twofold: (1) a novel approach for evaluating distribution system voltage areas while preserving data ownership and (2) the implementation of interactions between distribution network areas using the actor model. Unlike the previous sequential approach for evaluating the area connection voltages, which required a radial network topology, this study's area model reduction enables a more versatile approach. The area model reduction addresses issues of prolonged data waiting times and multiple points of failure within the previous approach. Notably, the presented evaluation for the reduced network model area connection reveals a significant increase in the differences in voltage magnitudes. Simulation and evaluation of area agents across four distinct cases elucidate the area-level interaction behavior during a fault event. Simulations demonstrate that the proposed distributed FLISR (DFLISR) approach can successfully restore service to an affected area. Varying message delays and message loss probabilities in each simulation case underscore their impacts on restoration times, ranging from 3 min and 32 s to 6 min and 19 s. In contrast, power is not restored in an area in one of our simulation cases.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Investigation of the temperature-dependent failure processes in PVD Cr-coated ZIRLO nuclear fuel cladding using in situ X-ray micro-tomography imaging

In this work, an accident tolerant fuel cladding system with Cr coating deposited using physical vapour deposition (PVD) method onto commercial Optimized ZIRLO™ was studied. The cladding tubes were machined into C-rings and loaded to failure under compression with real-time synchrotron micro-X-ray computed tomography (XCT) imaging at room temperature (RT), 345 °C, 650 °C and 950 °C in argon (Ar) atmosphere. The mechanical behaviour and failure processes were found strongly temperature-dependent where the Cr coating showed brittle fracture at RT and 345 °C, ductile fracture at 650 °C and a reversion to brittle fracture at 950 °C. Nanoindentation measurements and scanning electron microscopy (SEM) imaging were conducted on the materials after high temperature testing. It was found that recrystallisation of the Cr coating occurred at elevated temperatures, which significantly affected its local properties hence the failure behaviour at different temperatures. This work represents the first in situ 3D XCT observation of progressive failure processes in PVD Cr-coated ZIRLO claddings up to 950 °C providing critical insights into its brittle-to-ductile transition (BDTT) behaviour and subsequent ductile-to-brittle reversion with the increase in temperature. Moreover, results are compared with other PVD Cr-coated Zircaloy materials from open literature; the influences of the coating microstructure and local properties on the failure stress/strain and fracture processes are discussed.

Yuan, Guanjie↗

DOE OSTI2020

In-situ Detection of Glovebox Glove Degradation Prior to Glove Failure; Effects on Safety, Waste, and Operational Costs - 20402

Glovebox glove pressure decay leak testing and analysis of the data can greatly improve glovebox safety, minimize Transuranic (TRU) glove waste, and minimize operational cost. It is well known, the weakest point of containment on a glovebox is the glove. Mitigating unplanned openings in gloves is critical to minimizing operational and safety costs in glovebox operations. Mitigating unplanned glove openings due to glove failures will be discussed in this paper. The lack of an engineered solution to determine a gloves operational life in nuclear operations, has lead to use of theoretical and manual subjective methods to determine the life and safety of a glovebox glove. Whether the glove is inspected visually prior to use, or gloves are changed regularly to theoretically avoid failure, both the operators PPE and the room are being exposed to contamination, or un-necessary amounts of TRU glove waste are being generated. Millions of dollars yearly in operational costs are spent on glove failures due to loss of production, incident analysis, regulatory audits, clean up, and paperwork. In a nuclear application, a glove failure could contaminate an operator and laboratory, shut down the operation for weeks, potentially create a regulatory audit, and potentially create a media frenzy; the damages to the organization can be astronomical. Elimination of glove failures is possible by tracking glove material degradation and setting limits to allow glove change when it becomes necessary, prior to glove failure. Analytical pressure decay leak testing allows the detection of material degradation, and in turn the ability to limit operational glove failures. A German based company called MK Versuchsanlagen, e.K., has developed an advanced Glove Integrity Testing System. The system, with its use of proprietary RFID and special software technology, is unique in its capabilities. The system is capable to perform highly accurate regular glove testing on any size glovebox line in minimal time. The system records and can analyze a tremendous amount of system data that in turn can determine, for example, a safe glove change time prior to a glove material failure. This paper will show how an advanced Glove Integrity Testing System can detect glove material degradation and help determine a safe change point prior to glove failure. Pressure decay curves of new gloves and recorded effects of accelerated aging on the glove over time will be shown. The use of this technology in nuclear facilities can greatly improve glovebox operational safety, minimize glovebox glove TRU waste, and save organizations tremendous costs in downtime, clean up, documentation, and potential regulatory review. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Development of copper thiolate organometallic compound as thermal sensitive coating for energy storage system safety

Safety and reliability are primary concerns for the deployment of lithium-ion batteries, especially in electric vehicles (EV) and larger-scale energy storage systems (ESS). Current technology in battery management systems (BMS) includes cell voltage monitoring and positioning temperature sensors in selected locations. For a system with hundreds to thousands of individual batteries, single-point temperature monitoring is inadequate to detect hot spots and cell overheating, which could lead to thermal runaway. Here, we have developed a temperature-sensitive copper-thiol compound that can be directly coated onto battery pouch foils to enable early detection of thermal runaway. Upon reaching specific temperatures, this compound releases a sulfur-containing detectable gas, which can be identified using chemically specific gas sensors to trigger an early warning signal. Such a signal propagate through air offers broad signal coverage and enables a more comprehensive approach to large-area temperature monitoring. The Cu-ethanethiol coating is designed to release volatile gases when the substrate surface temperature exceeds 70 °C, with continuous outgassing as the temperature increases. The compound is composed of Cu, S, Cl, hydrocarbons and trace amounts of oxygen. Upon heating, the oxidation state of Cu(I) transitions to Cu (II), accompanied by gas release. Thermogravimetric analysis coupled with mass spectrometry correlated well with the onset of gas release temperature and emission of sulfur-containing volatile gases. Additionally, an acrylic overcoat is applied to enhance the adhesion of the thermally sensitive compound film to the battery pouch foil. This coating is expected to offer an additional safety layer for ESS, alerting possible thermal runaway events before a failure occurs, thereby allowing sufficient time to implement a mitigation plan.

Early warning systems↗

DOE OSTI2021

Novel Data Driven Noise Emulation Framework using Deep Neural Network for Generating Synthetic PMU Measurements

Sensors play a critical role in supporting day-to-day grid operations and they are essential to operator’s decision-making process. Furthermore, sensors and sensor behaviors need to be emulated with grid simulations to perform modeling studies and to design cutting edge power systems applications. Ensuring the accurate behavior of these applications requires accurate emulation of sensors and pertinent signals. However, most grid simulators and modeling tools assume either zero error scenarios or simplistic noise models that may not always correlate to real-world sensors. To address the above issue, this work presents an initial study on the noise characteristics of phasor measurement units (PMUs), along with models for recreating their unique noise signatures. The proposed methods (both analytical and machine-learning-based) provide a substantial increase in a sensor’s model fidelity, a feature that can be leveraged by an end-user application to yield more accurate system representations. The proposed methods were then applied to micro PMU data from the EPFL microgrid campus to extract sensor noise profiles. This data was used to train a deep learning model, which was tested to emulate the noise characteristics present in actual signals. Based on the observed results and the employed data-driven methodology, the proposed methods may be adapted to replicate the behavior of other grid sensors and power new applications capable of detecting sensor degradation and eventual device failures in near real-time.

PMU, noise emulation, synthetic measurements, deep↗

DOE OSTI2020

PV O&M Cost Model [SWR-21-14]

This tool presents a method for calculating costs associated with the operation and maintenance (O&M) of photovoltaic (PV) systems. The tool compiles details regarding the cost and frequency of multiple O&M services to estimate annual O&M costs ($/year) for each year of an analysis period, the net present value ($) of life cycle costs accumulated over the analysis period, and the reserve account amount ($) that might be required to fund unexpected repairs. The reserve account includes parts inventory and is important for providing a source of funds to make repairs quickly and avoid lost production. This method allows a detailed selection of services to perform based on system size, market served (e.g., residential, commercial, or utility), type and configuration of system components (e.g., micro-, string, or central inverter), and site and environmental conditions (e.g., pollen, bird populations) which is an improvement over simple per unit valuations of O&M costs ($/kW/year). This model also distinguishes costs that vary from year to year and increase at different rates over time as modeled by heuristic failure distributions (e.g., Weibull or Lognormal distribution) based on actuarial data for many of the services.

Walker, Andy↗

DOE OSTI2023

Tracing Service for Tracing-Driven Glidein Optimizations

Glideins, also known as pilots, play a pivotal role in the GlideinWMS framework: they provide tailored execution environments for user jobs to run on diverse, complex resources in a distributed setting. The framework includes several heuristics that determine the behavior of a Glidein such as how long to wait for new jobs, the wait time before a Glidein terminates etc., However, being aware of resources utilized and time exhausted during a Glidein failure and resubmission, for example, can be invaluable for its optimization. Our idea is to add a tracing service to the Glidein that will provide a closer observation of the end-to-end progress of a Glidein’s milestones and facilitates a better understanding of the overall framework as well as its reliability. The tracing service will not only gather more information about the Glidein itself to make way for optimizations but also allow user jobs to do the same.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Performance Analysis and Simulaion of the Hydraulic Scram System in TREAT Reactor

The Transient Reactor Test Facility (TREAT) at Idaho National Laboratory (INL) serves a vital role in nuclear fuel safety research, enabling transient experiments that simulate reactivity excursions and accident scenarios. Central to these operations is the transient control rod drive system (TCRDS), which drives rapid motion of the transient control rods such that TREAT can simulate rapid power changes typical of reactor accidents. The reliability and performance of this system are critical for protecting both fuel specimens and reactor infrastructure. This study presents the initial phase of a two-year investigation into the dynamics and reliability of the TREAT hydraulic TCRDS. Conducted in collaboration with INL, the research employs a combined computational and experimental approach to analyze the system's response time, pressure transients, and potential failure modes. Emphasis is placed on understanding how fluid characteristics influence the TCRDS’s ability to achieve both rapid power changes and mechanical stability. The TRDS and the skid that powers it will be analyzed throughout this investigation. Computational modeling using computational fluid dynamics (CFD) will simulate the hydraulic response under varying conditions. In parallel, experimental testing planned at INL will validate these models and capture key performance metrics. This paper outlines the system design, analytical framework, and modeling strategies that form the foundation for later testing. Ultimately, this work aims to support improvements to the TCRDS’s design and reliability, contributing to the broader goal of enhancing nuclear fuel safety and sustaining TREAT’s mission as a premier nuclear fuel test facility.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2023

Automatic Time Step Control to Resolve Hydromechanically Driven Fault Reactivation, Spontaneous Nucleation, and Seismic Arrest

Abstract A physical understanding of the progression from flow‐driven (quasi‐static) poromechanical deformation to dynamic fault rupture is critical to the resilient operations of several engineering systems. These processes are bridged by a progression from fault reactivation to the spontaneous nucleation of unstable sliding. Toward addressing this challenge, novel automatic time step size control methods are developed to enable accurate and efficient simulation of these dynamics and transitions from the first principles. The controllers combine local models for discretization error and Coulomb failure conditions to automatically adjust the time step size across several orders of magnitude. The methods do not require additional empirical or theoretical input and can resolve the pre‐rupture, interseismic, and seismic periods to the allowed accuracy. The computational results reveal that the proposed methods automatically capture the onset of reactivation and nucleation for homogeneous and heterogeneous fields. Hydrodynamic and structural heterogeneity lead to disparate critical nucleation sizes compared to those predicted by theory. The results highlight its potential in predicting induced seismicity in realistic subsurface engineering systems and at practical scales.

Environmental Sciences & Ecology↗

DOE OSTI2020

Continued Discussion of Failure Mode Modeling and Overall Component Reliability: Is the Data Missing or Censored?

This paper is a continuation of a paper presented at the 13th Probabilistic Safety Assessment and Management Conference, in which a discussion of modeling failure modes of complex components was presented; see Paulos and Smith (2016). The paper demonstrated how the typical method of treating failure modes as being exponential in nature may yield optimistic predictions when estimating how improvements to components will perform in the real world. Instead of relying on textbook methods, it is more accurate to model the failure modes as a race in time; unfortunately, this does not give a closed-form solution. This work uses a simulation to solve for the model of the world, and is compared to the standard methodology of treating the failure modes as exponential random failures. The standard method is shown to have optimistic predictions, which will lead to prediction errors when failure modes were removed or “fixed.” The failure mode methodology presented in the first paper treated the data as being censored when the test stopped. In this paper, we will compare the results from treating the data as both censored and missing, and comparisons will be shown showing which method is more accurate and under what conditions.

97 MATHEMATICS AND COMPUTING↗