Results for “Power Development” — Page 97

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

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

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

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

42 ENGINEERING↗

DOE OSTI2019

A Fast Load Control System Based on Mobile Distribution-Level Phasor Measurement Unit

The increase of renewable penetration in power grids calls for loads to participate in frequency regulation to avoid under-frequency load shedding after large resource contingencies. The motivation of our work is to fulfill a fast residential load control for frequency stability enhancement. For this purpose, a novel Mobile Distribution-level Phasor Measurement Unit (MDPMU) is developed for disturbance event detection, power mismatch estimation and fast load control. First, the systematic design of the MDPMU introduced. The proposed MDPMU has the major advantages of low cost and high frequency measurement accuracy. Second, the distribution-level measurement is utilized for the Rate Of Change Of Frequency (ROCOF) calculation. Upon detection of a power system frequency event, power mismatch is estimated at the early stage of the event. Details of a robust approach to calculate ROCOF and determine the event starting point are presented. Practical issues including the measurement reporting rate and estimation time are also examined. Finally, with the proposed control system, residential load responses can be controlled coordinately based on load availability and compensation prices offered by customers, providing adaptive frequency regulation service after large resource contingencies. The accuracy of frequency measurement and power mismatch estimation are evaluated via experimental analysis. The frequency stability improvement by load control is validated via PSS/E simulation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2016

Towards a Neutronic and Thermal-Hydraulic Safety Analysis of PWR Fuel Bow with SIMULATE5 and COBRA-TF

In the 1990's, collective fuel assembly bow was observed in the Ringhals PWRs in Sweden. Back then fuel vendors reinforced the fuel assemblies' dashpot, decreased hold-down spring forces, increased guide tube wall thickness, and introduced guide tube materials with higher creep resistance in order to improve dimensional stability. Nevertheless, twenty years later in 2010, the same kind of collective bow with S and C shape patterns started to appear in most of Germany's PWRs. At this time the SIMULATE5 (S5) core simulator with its delta-gap bow model (DGA) which was originally developed for safety analysis at Ringhals, could be used as an off-the-shelf solution to assess the impact of bow on Fq and FH. However, these two quantities are of secondary importance in German PWRs in normal operation because the most restricting licensing criteria set limits on DNBRmin values. For this purpose, a method was developed to extract S5 pin powers from DGA calculations and automatically generate COBRA-TF input files (CTF) to analyze DNBR values in the cores. In the following two sections, it is shown how the S5 model for DGA calculations has been verified with independent MCNP6 calculations in order to check its predictions on pin power changes for delta gaps up to 1 cm in size and how the existing licensed DNBR calculation methodology has been updated to bowed fuel assembly situations with the help of CTF. Finally, the applicability of the Doroschuk CHF correlation, which is the licensing standard in most German PWRs, is discussed. For the fuel bow patterns considered, it is assumed that only the gap between fuel assemblies change and that the pitch between fuel rods inside the assemblies remains largely unchanged. This approximation can be justified by the visual inspections conducted at the plants during the outages. Every calculation of the pin-power impact of delta-gaps in the core under operating conditions is only as good as the knowledge of the bow pattern. Measurements of fuel assembly bow at cold conditions have been made for some German PWRs for all the fuel assemblies in the core during plant outages. Together with methods developed by the fuel assembly vendors, a best-estimate bow pattern during operation could be reconstructed. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Conceptual designs of two petawatt-class pulsed-power accelerators for high-energy-density-physics experiments

Here, we have developed conceptual designs of two petawatt-class pulsed-power accelerators: Z 300 and Z 800. The designs are based on an accelerator architecture that is founded on two concepts: single-stage electrical-pulse compression and impedance matching [Phys. Rev. ST Accel. Beams 10, 030401 (2007)]. The prime power source of each machine consists of 90 linear-transformer-driver (LTD) modules. Each module comprises LTD cavities connected electrically in series, each of which is powered by 5-GW LTD bricks connected electrically in parallel. (A brick comprises a single switch and two capacitors in series.) Six water-insulated radial-transmission-line impedance transformers transport the power generated by the modules to a six-level vacuum-insulator stack. The stack serves as the accelerator’s water-vacuum interface. The stack is connected to six conical outer magnetically insulated vacuum transmission lines (MITLs), which are joined in parallel at a 10-cm radius by a triple-post-hole vacuum convolute. The convolute sums the electrical currents at the outputs of the six outer MITLs, and delivers the combined current to a single short inner MITL. The inner MITL transmits the combined current to the accelerator’s physics-package load. Z 300 is 35 m in diameter and stores 48 MJ of electrical energy in its LTD capacitors. The accelerator generates 320 TW of electrical power at the output of the LTD system, and delivers 48 MA in 154 ns to a magnetized-liner inertial-fusion (MagLIF) target [Phys. Plasmas 17, 056303 (2010)]. The peak electrical power at the MagLIF target is 870 TW, which is the highest power throughout the accelerator. Power amplification is accomplished by the centrally located vacuum section, which serves as an intermediate inductive-energy-storage device. The principal goal of Z 300 is to achieve thermonuclear ignition; i.e., a fusion yield that exceeds the energy transmitted by the accelerator to the liner. 2D magnetohydrodynamic (MHD) simulations suggest Z 300 will deliver 4.3 MJ to the liner, and achieve a yield on the order of 18 MJ. Z 800 is 52 m in diameter and stores 130 MJ. This accelerator generates 890 TW at the output of its LTD system, and delivers 65 MA in 113 ns to a MagLIF target. The peak electrical power at the MagLIF liner is 2500 TW. The principal goal of Z 800 is to achieve high-yield thermonuclear fusion; i.e., a yield that exceeds the energy initially stored by the accelerator’s capacitors. 2D MHD simulations suggest Z 800 will deliver 8.0 MJ to the liner, and achieve a yield on the order of 440 MJ. Z 300 and Z 800, or variations of these accelerators, will allow the international high-energy-density-physics community to conduct advanced inertial-confinement-fusion, radiation-physics, material-physics, and laboratory-astrophysics experiments over heretofore-inaccessible parameter regimes.

42 ENGINEERING↗

DOE OSTI2014

Power Electronics Thermal Management R&D (Presentation)

This project will investigate and develop thermal-management strategies for wide bandgap (WBG)-based power electronics systems. Research will be carried out to deal with thermal aspects at the module- and system-level. Module-level research will focus on die- and substrate-integrated cooling strategies and heat-transfer enhancement technologies. System-level research will focus on thermal-management strategies for the entire power electronics system to enable smart packaging solutions. One challenge with WBG device-based power electronics is that although losses in the form of heat may be lower, the footprint of the components is also likely to be reduced to reduce cost, weight, and volume. Combined with higher operational temperatures, this creates higher heat fluxes which much be removed from a smaller footprint, requiring advanced cooling strategies.

25 ENERGY STORAGE↗

DOE OSTI2022

Power Router for Distributing Solar in Communities (Solar Prize): Cooperative Research and Development, CRADA Number CRD-20-16809 (Final Report)

The American Made Solar Prize is a prize competition from the U.S. Department of Energy (DOE) that is designed to revitalize U.S. solar manufacturing. The competition aims to support the growth of U.S. solar manufacturing and reenergize American energy innovation by tapping into American's competitive spirit and the nation's unparalleled innovation ecosystem leveraging national labs, incubators, facilities and more.

14 SOLAR ENERGY↗

DOE OSTI2022

Needs and Opportunities for Testing of Hydropower Technology Innovations

Despite hydropower’s status as a well-established technology, changes in the global energy sector have prompted a variety of necessary hydropower technological innovations. Examples include efficient lowhead turbines, more flexible and dispatchable hydropower and pumped storage systems to complement variable and intermittent renewable resources, and technologies providing higher environmental performance. However, while innovative technologies are currently being proposed to meet these development challenges, small hydropower facility owners do not have sufficient risk-bearing capacity to adopt new, unvalidated technologies. This discourages manufacturers from bringing nascent technologies to market and stalls the technological growth of the sector. To reduce the risks associated with new technologies and promote further innovation, systemic (and sometimes unconventional) validation activities and new testing capabilities for hydropower are highly desired. These testing capabilities must demonstrate the safety, environmental acceptability, reliability, and performance of innovative technologies to quantify their value compared with existing technologies. Establishing these capabilities through dedicated testing facilities will be key to promoting hydropower growth in the United States. Following direction from the House Energy and Water Development Committee, the US Department of Energy’s Water Power Technologies Office (WPTO) has been tasked with understanding the state of hydropower testing in the United States. This scoping report discusses the needs and opportunities of hydropower testing in the United States, with a specific focus on small hydropower. Future developments will likely mostly target low-head sites with less than 30 ft (9.1 m) from new stream-reach developments, non-powered dam retrofits, and rehabilitation/upgrade of existing plants.

13 HYDRO ENERGY↗

DOE OSTI2019

A Pumped Thermal Energy Storage Cycle with Capacity for Concentrated Solar Power Integration

Pumped thermal energy storage (PTES) is a grid-scale energy management technology that stores electricity in the form of thermal energy. A number of PTES systems have been proposed using different thermodynamic cycles, including a variant based on a regenerated Brayton cycle that stores the thermal energy in liquid storage media (such as molten salts) via heat exchangers. This has several advantages, including the possibility to consider hybrid 'solar-PTES' systems employing technology developed by the concentrated solar power (CSP) industry. Such a hybrid system could charge the same hot stores using either solar energy or off-peak electricity (e.g, from nearby wind farms), increasing the capacity factor of the plant while employing the same heat engine during discharge. In this paper, two different configurations of solar-PTES systems are proposed and studied numerically: (i) a configuration in which an existing CSP plant is retrofitted with a Brayton heat pump, and (ii) a configuration in which a new hybrid plant uses the Brayton cycle both for charge and discharge. In both cases, the need to absorb and reject heat at conditions close to ambient temperature requires the Brayton cycle to incorporate intercooled stages at the cold side of the cycle. On the other hand, the intercooling process increases the minimum temperature of the cold stores, meaning that widely available and nonflammable antifreeze solutions (such as water-ethylene glycol) may be used as the cold storage medium.

14 SOLAR ENERGY↗

DOE OSTI2023

Suspending democratic (dis)belief: Nonliberal energy polities of solar power in Morocco and Tanzania

This paper proposes the concept of technodemocratic imaginaries (TDIMs) to supplement the widely-used framework of sociotechnical imaginaries (STIMs) for analyzing nonliberal political contexts in energy social science research. Taking the power of coproductionist analysis of STIMs seriously, TDIMs highlight the inherent instabilities within overarching STIMs by arguing that not only are particular groups marginalized and excluded but that they continue to practice and mobilize their own imaginaries of collective governance and justice vis-à-vis energy systems. In contrast, the existing idea of contested STIMs, in which a shared mode of knowledge politics undergirds different imaginaries, casts aside subaltern modes of political engagement and knowledge-making. TDIMs expand conceptions of democracy to include shared practices of credibility in nonliberal political orders. The intent is not to promote democratic relativism but rather to ask scholars and international energy-access practitioners to suspend their democratic disbelief when studying energy matters in so-called nonliberal contexts. We develop the concept of TDIMs by comparing two African nation-states–Morocco and Tanzania–to show how the states and subaltern groups do (or do not) develop TDIMs related to solar power. While international governance organizations often portray Morocco as authoritarian and Tanzania corrupt, each state differently experienced colonization and decolonization and practices different relationships with domestic subaltern groups. Whereas low-income citizens and indigenous groups seek integration into the Moroccan state’s STIM, the Maasai in Tanzania chart their own TDIM separate from the state and international development groups.

14 SOLAR ENERGY↗

DOE OSTI2024

Joint Expansion Planning of Power and Water Distribution Networks

This research considers the joint expansion planning of power and water distribution networks, which are interdependent at various levels. We consider the dependency arising through the power consumption of pumps and develop models for integrating new components into existing networks. Then, we formulate the joint expansion planning as a Mixed Integer Nonlinear Program (MINLP). Applying this MINLP to a small-scale test network, we illustrate the advantages offered by joint expansion planning, such as increased flexibility and reduced costs and redundancy, over independently expanding power and water distribution networks.

expansion planning↗

DOE OSTI2023

Cost analysis of distributed storage in AC and DC microgrids

Building and microgrid designs with highly-distributed electrical storage have potential advantages over today's conventional topologies with centralized storage. Herein this paper studies the capital cost benefits of several residential behind-the-meter distributed-storage topologies, including AC and DC versions of systems with load-packaged batteries and resilient sub-networks. The study begins by defining the block configuration of each topology. This work then develops a model for the cost of the power electronics necessary to interface with the storage elements. Finally, the analysis develops a model for the total cost of each storage topology, incorporating the installation and soft costs. The results suggest that while the cost of power electronics is lower in centralized topologies, the total cost is lower for distributed storage due to the avoided costs of installation and permitting. This paper also explores the benefits of load-packaged batteries for savings in electrical infrastructure.

25 ENERGY STORAGE↗

DOE OSTI2016

Understanding nucleic acid structural changes by comparing wide-angle x-ray scattering (WAXS) experiments to molecular dynamics simulations

Wide-angle x-ray scattering (WAXS) is emerging as a powerful tool for increasing the resolution of solution structure measurements of biomolecules. Compared to its better known complement, small angle x-ray scattering (SAXS), WAXS targets higher scattering angles and can enhance structural studies of molecules by accessing finer details of solution structures. Although the extension from SAXS to WAXS is easy to implement experimentally, the computational tools required to fully harness the power of WAXS are still under development. Currently, WAXS is employed to study structural changes and ligand binding in proteins; however, the methods are not as fully developed for nucleic acids. Here, we show how WAXS can qualitatively characterize nucleic acid structures as well as the small but significant structural changes driven by the addition of multivalent ions. We show the potential of WAXS to test all-atom molecular dynamics (MD) simulations and to provide insight into understanding how the trivalent ion cobalt(III) hexammine (CoHex) affects the structure of RNA and DNA helices. We find that MD simulations capture the RNA structural change that occurs due to addition of CoHex.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

The aging of nuclear power plant electrical cables has been the subject of substantial research and development (R&D) projects in the nuclear industry, national and international laboratories, universities, and vendor organizations for several years. More specifically, these R&D efforts were conducted to develop equipment and techniques for assessing age-related degradation of in-service cables in nuclear facilities including power plants, research reactors, waste facilities and fuel fabrication plants. In recent years, cable R&D efforts in the nuclear arena have also included work to develop new cables for the next generation of reactors. Over time, exposure to harsh environmental conditions such as elevated temperatures, radiation, and humidity in nuclear installations can result in age-related degradation and failure of cables. In the current fleet of nuclear reactors, there are thousands of miles of cabling installed in each plant and many of these cables are exposed to these harsh environmental conditions. For these cables, the jacket and insulation polymers harden and become brittle over time, making them more susceptible to crack formation and growth, moisture intrusion, and other mechanisms that can lead to cable failure. Moreover, the existing U.S. fleet of 98 nuclear reactors has an average operating age of 38 years. Many of these nuclear power plants have applied for and almost all have been granted regulatory approval for license renewals to operate for 60 years, 20 years beyond their original 40-year life. Further, subsequent license renewals (SLRs) are underway with a few commercial nuclear power sites already approved to operate up to 80 years. As these reactors pursue operating life extensions, utilities must find a way to address issues associated with age-related degradation of cables. Designers of small modular reactors are also in need of technologies to evaluate the performance of cables that will be installed in harsher environments (e.g. higher temperatures, radiation doses, dose rates, etc.) than those present in current-generation reactors. Today, a variety of cable condition monitoring (CM) techniques have been developed and successfully used in nuclear facilities. These techniques are used to identify age-related degradation and assess the condition of cables to determine if their performance characteristics have changed with age. However, objective criteria must be developed for these CM tests to help quantify cable condition and thereby develop repair and replacement schedules. With operating life extending to 80 years and more SLRs on the horizon, both nuclear facilities and regulators need an objective means to determine the aged condition of cables.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

The aging of nuclear power plant electrical cables has been the subject of substantial research and development (R&D) projects in the nuclear industry, national and international laboratories, universities, and vendor organizations for several years. More specifically, these R&D efforts were conducted to develop equipment and techniques for assessing age-related degradation of in-service cables in nuclear facilities including power plants, research reactors, waste facilities and fuel fabrication plants. In recent years, cable R&D efforts in the nuclear arena have also included work to develop new cables for the next generation of reactors. Over time, exposure to harsh environmental conditions such as elevated temperatures, radiation, and humidity in nuclear installations can result in age-related degradation and failure of cables. In the current fleet of nuclear reactors, there are thousands of miles of cabling installed in each plant and many of these cables are exposed to these harsh environmental conditions. For these cables, the jacket and insulation polymers harden and become brittle over time, making them more susceptible to crack formation and growth, moisture intrusion, and other mechanisms that can lead to cable failure. Moreover, the existing U.S. fleet of 98 nuclear reactors has an average operating age of 38 years. Many of these nuclear power plants have applied for and almost all have been granted regulatory approval for license renewals to operate for 60 years, 20 years beyond their original 40-year life. Further, subsequent license renewals (SLRs) are underway with a few commercial nuclear power sites already approved to operate up to 80 years. As these reactors pursue operating life extensions, utilities must find a way to address issues associated with age-related degradation of cables. Designers of small modular reactors are also in need of technologies to evaluate the performance of cables that will be installed in harsher environments (e.g. higher temperatures, radiation doses, dose rates, etc.) than those present in current-generation reactors. Today, a variety of cable condition monitoring (CM) techniques have been developed and successfully used in nuclear facilities. These techniques are used to identify age-related degradation and assess the condition of cables to determine if their performance characteristics have changed with age. However, objective criteria must be developed for these CM tests to help quantify cable condition and thereby develop repair and replacement schedules. With operating life extending to 80 years and more SLRs on the horizon, both nuclear facilities and regulators need an objective means to determine the aged condition of cables.

36 MATERIALS SCIENCE↗

DOE OSTI2021

An Analysis Framework for Distribution Network DER Integration Analysis in India: Distributed Solar in Tamil Nadu

This report is part of a two-part series that represents a year-long collaboration with the Tamil Nadu Generation and Distribution Corporation Limited (TANGEDCO) on power sector planning. The first report in this series, the Pathways for Tamil Nadu’s Electric Power Sector 2017-2030 report outlines NREL’s work with TANGEDCO's electricity sector planning department to develop a model of the State’s power system and evaluate multiple scenarios of system growth given resource constraints, costs of technologies, and power sector policies. This second report in this series focuses on the rapidly transforming distribution network in the State. The report outlines a framework developed by NREL with TANGEDCO's distribution utility to quickly and accurately analyze the impacts of integrating renewable energy, specifically rooftop solar PV onto Tamil Nadu's distribution system. Together these studies help to prepare Tamil Nadu for a rapidly transforming power system.

14 SOLAR ENERGY↗

DOE OSTI2019

NECQST: Novel Electronics for Cryogenic Quantum Sensors Technology

Development of low-noise cryogenic readout circuits for SNSPDs based on state-of-the art, commercially available SiGe HBT technology, operating at a range of 1-4 Kelvin. Targeting a reduction of the timing jitter of SNSPDs (from the current record of 2.7 ps FWHM at 400 nm), and a reduction in the power dissipation allowed by the development of dedicated low-noise cryogenic amplifiers, which will enable the scaling of ultra-low-jitter SNSPDs to large arrays. Such performance advances will directly benefit the Caltech/Fermilab INQNET (Intelligent Quantum Networks & Technologies) program, which aims to demonstrate high-rate quantum communication at Fermilab.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Community-Centric Microgrid Feasibility Analysis Framework to Accelerate Resilience of Island Communities

Marine energy offers a reliable energy solution for island and coastal communities, which often lack traditional local generation, to support their transition to energy independence and reduce reliance on externally imported fuels. Successful deployment of new technologies in these isolated locations requires community acceptance and approval from the outset, as these communities typically lack the financial and technical resources to operate and maintain new systems. This report presents a community-centric microgrid planning framework for remote coastal and island communities. Community engagement is integrated as the first step in the planning process, incorporating community profiles and visions into energy development scenarios. A case study was conducted in St. George, Pribilof Islands, Alaska, which relies entirely on diesel yet has significant wind and wave energy potential. Community engagement revealed a unique history and current economic status, with an interest in adopting advanced energy technologies despite past failures. Various microgrid configurations were optimized, considering different technologies to meet current and future energy needs while balancing cost and energy resilience. Wave energy converters (WECs) were a key component, integrated with other energy sources using the Xendee optimization tool. The Marine Energy Microgrid Toolkit, developed as part of this work, uses commercial power system analysis tools to optimize and analyze microgrid scenarios. The developed framework and toolkit can be applied to island and coastal communities to enhance resilience and support microgrid deployments. Future enhancements will include incorporating new marine resources, developing dynamic models, and automating the integration of Xendee and PowerFactory simulations.

02 PETROLEUM↗