AC-LGAD silicon detectors with alternate gain layer for improved reliability.
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36 MATERIALS SCIENCE↗
SEARCH · Engineering Papers
Results for “Reliability”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Virtual Reliability Software for Real Time Detection of Failures at PV Plants
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14 SOLAR ENERGY↗
Performance Enhancement of Hydrokinetic Arrays Using Reliable, Low-cost Dynamic Components
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13 HYDRO ENERGY↗
Machine Learning-Based Composite Power System Reliability Assessment
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Nguyen, Nga↗
Powering Up Secure and Reliable Operations at the Port of Honolulu's Kapalama Container Terminal
The National Laboratory of the Rockies (NLR) is providing resilience planning support to the Pasha Group, the operator of Kapalama Container Terminal (KCT) at the Port of Honolulu, by exploring how distributed clean energy resources could help the terminal sustain a 36-hour outage and continue emergency operations. The Department of Energy's Energy Transitions Initiative (ETI) aims to advance self-reliant island and remote communities by promoting resilient, affordable, and sustainable clean energy resources.
25 ENERGY STORAGE↗
New Report Highlights LAMP's Role as a Robust and Reliable System for Wave Energy Converter Testing
Harnessing the power of waves requires more than just putting devices in the ocean - it takes tools that can refine and accelerate innovation before the first deployment. That's where NLR's largeamplitude motion platform, or LAMP, comes in. LAMP is a six-degree-of-freedom motion system designed to replicate the response of a wave energy converter (WEC) device in realistic ocean conditions. By letting researchers evaluate WEC performance in a safe, controlled lab environment before moving offshore, LAMP helps accelerate innovation while reducing risk. An NLR report, titled Initial Characterization of the NLR LargeAmplitude Motion Platform (https://www.nrel.gov/docs/fy26osti/93733.pdf), provides a deeper understanding of LAMP's capabilities and also lays the groundwork for future advancements in WEC testing methodologies. Researchers studied LAMP's amplitude and frequency limits across different payloads and collected data from 16 test profiles. Testing demonstrated that platform accuracy remained consistent across all payloads evaluated; researchers expect similar accuracy up to LAMP's 10,000-kilogram capacity limit. The measured position limits for single degrees of freedom experienced by WECs, including surge, sway, heave, roll, pitch, and yaw, also exceeded the original manufacturer specifications, providing new insight into the true boundaries of the system.
16 TIDAL AND WAVE POWER↗
From Machine Learning to Machine Reasoning: A Model-based Approach to Analyze Equipment Reliability Data
In current nuclear power plants (NPPs) a large amount of condition-based data which can be used to assess and monitor component health and performance. Assessing component health from such data can be performed with a large variety of methods. While the analysis of numeric data can be performed with several methods, the extraction of information from textual data remains a challenge. Currently employed natural language processing (NLP) methods do not really provide quantitative information that might be contained in IRs. In addition, the integration of numeric and textual data to identify possible causal relationships between data elements is still an unresolved challenge. This paper presents an approach to extract information from textual (e.g., incident or maintenance reports) and numeric data that relies on model based system engineer (MBSE) models. MBSE are diagrams designed to represent system and component dependencies (from both a form and functional point of view). In our approach, MBSE models emulate system engineer knowledge about component/system architecture. NLP methods are employed to perform syntactic and semantic analyses. Syntactic analysis analyzes the grammatical structure of a sentence while semantic analysis is designed to analyze the logic structure of a sentence. An innovative element of our approach is that semantic analysis uses MBSE models to identify links between textual elements. Similarly, numeric data is directly linked to elements of the MBSE models in order to map which functions are being monitored.
97 - MATHEMATICS AND COMPUTING↗
Overview of Human Reliability Analysis Research at Idaho National Laboratory
Introducing following HRA topics to visitors from Naval Nuclear Labs. - Dynamic HRA Method and Software (LWRS) - HRA Data Collection (LWRS) - HRA Consultation (KINS) - HRA for Advanced Nuclear Reactors (Hobby) - HRA for Non-Nuclear Industries (BEES)
99 - GENERAL AND MISCELLANEOUS↗
Reliable Power for Remote Applications
Optical power beaming - using lasers to transmit energy across distances - could change how remote devices receive power. The National Laboratory of the Rockies (NLR) seeks partners to explore the next stage in long-distance power beaming for terrestrial and space-based applications.
14 SOLAR ENERGY↗
Superior model for fault tolerance computation in designing nano-sized circuit systems
As CMOS technology scales nano-metrically, reliability turns out to be a decisive subject in the design methodology of nano-sized circuit systems. As a result, several computational approaches have been developed to compute and evaluate reliability of desired nano-electronic circuits. The process of computing reliability becomes very troublesome and time consuming as the computational complexity build ups with the desired circuit size. Therefore, being able to measure reliability instantly and superiorly is fast becoming necessary in designing modern logic integrated circuits. For this purpose, the paper firstly looks into the development of an automated reliability evaluation tool based on the generalization of Probabilistic Gate Model (PGM) and Boolean Difference-based Error Calculator (BDEC) models. The Matlab-based tool allows users to significantly speed-up the task of reliability analysis for very large number of nano-electronic circuits. Secondly, by using the developed automated tool, the paper explores into a comparative study involving reliability computation and evaluation by PGM and, BDEC models for different implementations of same functionality circuits. Based on the reliability analysis, BDEC gives exact and transparent reliability measures, but as the complexity of the same functionality circuits with respect to gate error increases, reliability measure by BDEC tends to be lower than the reliability measure by PGM. The lesser reliability measure by BDEC is well explained in this paper using distribution of different signal input patterns overtime for same functionality circuits. Simulation results conclude that the reliability measure by BDEC depends not only on faulty gates but it also depends on circuit topology, probability of input signals being one or zero and also probability of error on signal lines.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
High Temperature Optocoupler for 3D High Density Power Modules
The goal of this proposed research is to develop a reliable high-temperature optocouplers, which can operate at 250°C with at least ten-year lifetime, and replace isolation transforms as the galvanic isolation solution for the 3D integration of high density power modules. The electrification of future transportations (i.e., electric vehicles) will continuously drive the demand for high density power modules. Optocouplers (i.e., packaged light emitter and detector) as a promising candidate to replace bulky isolation transformers are highly desirable to facilitate the continuous scale-down of gate driver circuitry that will lead to 3D high density power modules and achieve disruptive performance in terms of thermal management, power density, power efficiency, reliability and operating environments. However, regular semiconductor optoelectronic materials and devices have significant difficulty functioning in the harsh environments designated for high density power module usage (such as operation at high temperatures). Ultimately, it is not the intrinsic properties of power devices that prevent their use at higher temperatures, but rather the low voltage electronics needed to drive them and the packaging that surrounds them. The typical operating temperature for optocouplers is only up to 100°C, due to the limitations of light emitting diode (LED) devices inside and packaging materials. A systematic characterization methodology will be developed to analyze the performance, lifetime and reliability of LED devices and distinguish multiple failure mechanisms at high temperatures. An original methodology of “design for reliability” will be developed to design the optoelectronic devices with high reliability and long lifetime at high temperatures. A new architecture of high temperature high reliable optocouplers will be developed, fabricated and demonstrated with continuous operating at 250°C. The development of efficient, reliable high density 3D power modules is the foundation for energy efficiency and energy reliability. Enabled with advanced 3D integration and packaging technologies, high density power module solutions can achieve much more superior performance over the conventional discrete solutions in terms of efficiency, thermal management and power density. The proposed concept of high temperature optocouplers as the galvanic isolation solution for high density power modules will bring together interdisciplinary research involving the wide bandgap materials, optoelectronics, high reliable device design, electronics packaging and power modules. A streamline of skilled personnel would be trained including graduate and undergraduate students, local engineers and scientists which are in great demand to both academia and optoelectronics industry. The proposed research topics, such as, solid state lighting and high temperature device reliability, are currently of major interest at the Department of Energy, in particular, Sandia National Laboratories. This project can enhance collaborations between the University of Arkansas (UA) and Sandia National Laboratories. The findings of the proposed research are expected to be integrated into high density 3-D power modules at the Engineering Research Center for Power Optimization for Electro-Thermal Systems (POETS).
42 ENGINEERING↗
Management of Risks Associated with Application of Novel Materials in Novel Operating Environments in Novel Reactor Designs
There is currently no widely agreed, detailed general method for licensing a novel plant incorporating novel materials (or materials being deployed in novel environments); in many such situations, there are no directly applicable engineering code cases for decision-makers (including regulators) to rely on. This paper discusses a framework for solving this problem that is based on the Reliability and Integrity Management (RIM) approach delineated in ASME BPVC Section XI Division 2. NRC Regulatory Guide 1.246, Rev. 0, endorses, with conditions, the subject portion of the ASME Code. The proposed framework is meant to support development of a licensing case by addressing certain technical challenges. The framework discussed here is compatible with the Licensing Modernization Project, but applying it in a specific case will call for advances in the state of practice, if not the state of the art. The RIM approach calls for applicants to (a) allocate reliability targets to plant structures, systems, and components (SSCs), (b) show that they are able to relate the currently observed physical condition of each SSC in the program to its failure probability well enough to determine whether the target reliability allocations are being satisfied, allowing for uncertainty related to the novelty of the materials/designs/operating environments, and (c) be able to demonstrate that the proposed program of surveillances will reliably detect unacceptable degradation of an SSC before SSC failure occurs. These challenges are discussed in the paper, and a potentially applicable modeling approach based on cumulative damage rather than failure rates is briefly illustrated.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
R&D to Ensure a Scientific Basis for Qualification Tests and Standards (Final Report)
Project return on investment in a photovoltaic (PV) system depends increasingly on maintaining high energy yields, and the system lifetime is a major factor in levelized cost of electricity (LCOE). Thus, the rate of PV deployment and the success of these assets depends upon reliable long-term power generation. The overarching objective of this program is to improve photovoltaic (PV) module reliability via development of tests and standards. Where reliability problems or risk are discovered, we can design tests to ensure that these liabilities don't affect future generations of products. Customers can use these tests to understand which products are susceptible to certain degradation mechanisms, and manufacturers can use the tests to design unwanted characteristics out of their products. The work under this program identifies PV reliability needs, performs characterization that provides scientific understanding of targeted degradation mechanisms, and translates those data into practical and predictive test protocols and standards. Major accomplishments include: A model for polarization-type potential induced degradation (PID-p) was developed and validated against experimental data. NREL is currently leading a new edition of IEC 62804-1 for PID detection. PID-p can cause large losses in current and voltage for some module designs on cloudy days. Finite element modeling (FEM) and experiment was used to determine when cells crack in a module. It was shown that cells in landscape orientation are much more likely to crack than those on portrait orientation. Shortly thereafter, the first products with portrait-oriented cells were introduced. Studies of how to test for light and elevated temperature degradation (LeTID) culminated with the publication of IEC TS 63342. Software to predict the progression of LeTID was developed, validated, and made publicly available. Field validated tests and international standards for durability of PV module coatings abrasion, backsheets, and encapsulants were developed. Examples are IEC 62788-1-1, IEC 62788-2 ED2, IEC TS 62788-7-2, IEC 62788-7-3 ED1, IEC 63209-2. NREL led the development a high-temperature testing technical specification, and published guidelines that enable installers to determine whether higher-temperature testing is needed, simply based on location and mounting configuration. In a number of our case studies, variations in the bills of materials or workmanship have been associated with variations in reliability. These observations emphasize the importance of quality assurance to reliability. A framework for criticality (i.e. Pareto) analysis was developed and published. The framework helps us and other researchers determine what problems should be addressed for reliability research to have the biggest industry impact. NREL continues to participate actively in international standards development and stakeholder engagement activities, including organizing an annual PV Reliability Workshop. These activities are important for ensuring we address issues that are relevant and timely, and that we convey our results to those who may benefit.
14 SOLAR ENERGY↗
Parametric Design Study of a Power Electronics Package
The lifetime of a power electronics package is, to a large extent, determined by the reliability of its bonded interfaces under major loading conditions in an operational environment. Based on the application-level requirements of the package, bonded interface material is selected based on the results obtained from accelerated tests such as thermal cycling and power cycling. In addition to evaluating the reliability through accelerated tests, it is important to consider the impact of other component layers on the thermomechanical performance of the interface material, both from a material and geometric perspective. The co-efficient of thermal expansion (CTE) mismatch introduced by the use of different materials within a package and its structural design plays a critical role in determining the interface material reliability. In this paper, we present the results of a parametric modeling study of a power electronics package under thermal cycling in which the materials and geometric design of the different component layers were varied with respect to a baseline design to understand their impact on the reliability of the interface material. We chose the volume-averaged strain energy density per cycle computed at the corner region of the interface material as the metric for the reliability comparisons. Our results indicate that in addition to the CTE mismatch, the stiffness of individual component layers has a major impact on reliability. Among the different baseplates that we studied, aluminum silicon-carbide baseplates offered superior reliability over their copper and aluminum counterparts. We also found that the magnitude of the impact of stiffness variation—amongst the adjacent layers—on the reliability of the solder joint is dependent on the inherent CTE mismatch between the layers.
47 OTHER INSTRUMENTATION↗
Integrated Sustainable Product Design With Warranty and End-of-Use Considerations
The concept of integrated sustainable product design has recently emerged, aiming to incorporate downstream life cycle performance into the initial product design to enhance sustainability. Various sustainable product design tools based on life cycle assessment or quality function deployment have been established while the impact of reliability on circular practices has received limited attention. Recognizing the critical role of product reliability in post-design performance, this paper develops a product design optimization model that considers the warranty performance and the effect of end-of-use options. The model takes into account the effect of uncertain operating conditions on product reliability. Two optimization goals including the minimization of expected unit life cycle cost and environmental impact are achieved by the model. To demonstrate the benefits of the integrated approach, the model is applied to an electric motor design problem. The results highlight that integrating end-of-use options in the early design phase leads to adjustments in component selection and reliability design. Moreover, the circular utilization of used products enables cost savings throughout the product’s life cycle and contributes to environmental impact reduction. Finally, the study analyzes the effects of operating conditions, warranty policies, and take-back prices for used products on design decisions, providing valuable insights for product designers.
Integrated design↗
Adaptive Protection and Validated Models to Enable Deployment of High Penetrations of Solar PV (PV-MOD)
The availability and validation of various PV models in commercial tools differ, with some models not yet thoroughly validated for advanced inverter functionalities and reliable performance under weak system conditions. Many existing models do not fully incorporate new inverter control functions, which can affect system stability. The increasing deployment of solar PV and other inverter-based resources (IBRs), including distributed energy resources (DERs), is influencing the reliable operation of protection schemes in distribution systems and microgrids. Emerging adaptive protection schemes (APS) offer new opportunities for protecting these systems during varying configurations and DER operating conditions, though their demonstration and validation remain limited. Adaptive protection schemes face similar challenges, as they are typically designed for specific configurations. There is a growing need for tools and methodologies to streamline the deployment of adaptive protection for safe and reliable DER integration. The project main objective was to develop and validate high-fidelity generic models of solar PV facilities for stability, protection, EMT, and QSTS analyses. This objective was achieved, and these models can now be integrated into commercial software tools, enabling utilities, vendors, and developers to study high-penetration PV systems more confidently. The project also demonstrated advanced applications of these models, including the design and deployment of adaptive protection schemes in high-penetration field applications and microgrids, supporting grid safety and reliability. Several milestones were reached by the end of the project. A sophisticated inverter test plan was developed, and inverters representative of the North American marketplace were selected. EPRI and NREL tested various inverters, conforming to IEEE standards. Improvements were made to existing generic models of IBR units, IBR plants, and aggregated feeders for various analyses. The first generic electromagnetic transient (EMT) model for a solar PV plant was developed, conforming to IEEE Std 2800™-2022 and validated against laboratory measurements of a 2.2 MVA large-scale battery energy storage system (BESS) inverter. That model was then used to produce reference responses illustrating examples of validated and verified IBR plant models that pass or fail tests for technical minimum capability and performance as specified in the IEEE standard. The developed, tested, and validated generic models can be used for transmission planning, stability assessments, expansion planning, and evaluating potential future IBR interconnection requirements. They can also support interconnection screens and conformity assessments of IBR plants, including solar PV. The project significantly contributed to the ongoing standardization and model-based representation and verification of IBR responses. The project further addressed challenges of common distribution protection schemes with increasing deployment of DER by developing, validating, and demonstrating adaptive protection schemes (APS) that can improve the reliable and safe integration of DER into distribution systems. New APS were designed using improved DER models for three common distribution systems: a radial feeder, a meshed network, and a microgrid. Modeling and hardware-in-the-loop (HIL) testing of the APS were conducted, successfully showing their effectiveness and selectivity. Proof-of-concept field demonstration was achieved for two APS, i.e., one on a radial feeder and another one in a microgrid. Field demonstration could not be achieved for the APS on a meshed network, primarily due apprehension of one utility partner and also due to limited access to the protective algorithms in the network protectors. Guidelines developed from the lessons learned in the project lay out the general process followed in the design, installation, and commissioning of APS for various distribution systems. Distribution utility partners’ apprehension about field demonstration of the new APS were addressed—with varying success—by taking a stepped risk-management approach of modeling of a wide range of sensitivities first, performing in-depth proof-of-concept testing in the laboratory including HIL next, and finally deliberately implementing and commissioning the actual protection equipment and algorithms into parts of—or in parallel operation to—the three real distribution systems. Future work should include pilot projects that further show the acceptable performance of the developed APS before these schemes be rolled out more widely. Inclusion of both utility and original equipment manufacturers (OEMs) in future projects could increase chances of successful field demonstration. Despite challenges in achieving the field demonstration goal of the project for all three APS, the research significantly contributed to the innovation of adaptive protection solutions for scalable and reliable DER integration into distribution systems. This project significantly enhances the understanding of the impact of using appropriate inverter models on distribution and transmission (T&D) systems. By addressing the limitations of existing generic models, the project introduces high-fidelity models for stability, protection, electromagnetic transient (EMT), and quasi-static time series (QSTS) analyses. These models, integrated into commercial software tools, enable utilities, vendors, and developers to confidently study high-penetration PV systems. The project also demonstrates advanced applications, including adaptive protection schemes (APS) for distribution systems and microgrids, ensuring grid safety and reliability. The technical effectiveness and economic feasibility of the methods are evident through the development and validation of sophisticated inverter test plans and the selection of representative inverters. Testing by EPRI and NREL on retail, commercial, and utility-scale inverters, conforming to IEEE standards, underscores the robustness of the models. Improvements to existing generic models for various analyses further enhance their validity and applicability. The project also identifies gaps in common distribution protection schemes and designed new APS using improved DER models, demonstrating their effectiveness through modeling and hardware-in-the-loop (HIL) testing. The project’s benefits to the public are manifold. By advancing the standardization and model-based representation of IBR response, it supports transmission planning, stability assessments, and future IBR interconnection requirements. The generic models can facilitate better communication between transmission planners and developers, supporting expected IBR plant capability and performance. Additionally, the development of APS for radial feeders, meshed networks, and microgrids supports the integration of distributed energy resources (DERs) into distribution systems, enhancing grid reliability and safety. The project’s emphasis on thorough testing and simplicity in design ensures practical and scalable solutions for DER integration.
14 SOLAR ENERGY↗
Optimized Generator Designs for the DTU 10-MW Offshore Wind Turbine using GeneratorSE
Compared to land-based applications, offshore wind imposes challenges for the development of next generation wind turbine generator technology. Direct-drive generators are believed to offer high availability, efficiency, and reduced operation and maintenance requirements; however, previous research suggests difficulties in scaling to several megawatts or more in size. The resulting designs are excessively large and/or massive, which are major impediments to transportation logistics, especially for offshore applications. At the same time, geared wind turbines continue to sustain offshore market growth through relatively cheaper and lightweight generators. However, reliability issues associated with mechanical components in a geared system create significant operation and maintenance costs, and these costs make up a large portion of overall system costs offshore. Thus, direct-drive turbines are likely to outnumber their gear-driven counterparts for this market, and there is a need to review the costs or opportunities of building machines with different types of generators and examining their competitiveness at the sizes necessary for the next generation of offshore wind turbines. In this paper, we use GeneratorSE, the National Renewable Energy Laboratory's newly developed systems engineering generator sizing tool to estimate mass, efficiency, and the costs of different generator technologies satisfying the electromagnetic, structural, and basic thermal design requirements for application in a very large-scale offshore wind turbine such as the Technical University of Denmark's (DTU) 10-MW reference wind turbine. For the DTU reference wind turbine, we use the previously mentioned criteria to optimize a direct-drive, radial flux, permanent-magnet synchronous generator; a direct-drive electrically excited synchronous generator; a medium-speed permanent-magnet generator; and a high-speed, doubly-fed induction generator. Preliminary analysis of leveled costs of energy indicate that for large turbines, the cost of permanent magnets and reliability issues associated with brushes in electrically excited machines are the biggest deterrents for building direct-drive systems. The advantage of medium-speed permanent-magnet machines over doubly-fed induction generators is evident, yet, variability in magnet prices and solutions to address reliability issues associated with gearing and brushes can change this outlook. This suggests the need to potentially pursue fundamentally new innovations in generator designs that help avoid high capital costs but still have significant reliability related to performance.
17 WIND ENERGY↗
Predictive Analytics for Hydropower Fleet Intelligence
A primary challenge in hydropower industry is the ability to maintain cost-competitiveness, reliability, and security of hydropower assets through evolving power system contexts and aging of the fleet. Maintaining cost-effective and reliable operations under these conditions is expected to require new modernization and maintenance paradigms for changing contexts. Changes in existing practices for O&M will require an understanding of the current state and health of hydropower assets, and the impact of changing paradigms on asset health and reliability. The Hydropower Fleet Intelligence project is developing and evaluating standardized methodologies and analysis tools for data-driven asset reliability and management technologies for hydropower, leading to eventual predictive maintenance planning, repair/replacement decision making, and asset-reliability and cost-optimized operations. A key question is the feasibility of using existing data sets at hydropower facilities to perform assessments of asset reliability. This document uses data from hydropower facilities to assess the potential for using available analytics methods for asset reliability estimates. In addition to reliability assessments, the feasibility of using existing analytics techniques for several other potential applications is discussed. Finally, a case study that a data-driven model is trained to learn nominal operations via vibration data from an asset of a certain plant, and then utilized to identify anomalies on a similar asset from a different plant, highlighting the generic use of proposed Prognostics and Health Management (PHM) approaches.
Yucesan, Yigit↗