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At least 181 records · Page 10

Detecting thermal crack growth on a large additive manufactured structure using acoustic emission

Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structures (reaching hundreds of pounds) develop thermal-residual stress during cool-down and can eventually crack, turning the structure into waste. Acoustic emission (AE), a passive non-intrusive global nondestructive evaluation (NDE) technique, was used to monitor crack growth and can provide the right tools that can be used for feedback loop for corrective action. This research performs thermal testing on a large AM mold with preexisting cracks, in an attempt to monitor crack growth using AE. AE was able to detect, identify and locate the crack source by means of acoustic features, waveform characteristics, spectrum analysis, and difference in arrival times.

Spencer, Ryan↗

Continuous thermostat setpoint monitoring and correction (Thermostat setpoint correction) v1.0

The Continuous Thermostat Setpoint Monitoring and Correction software is a set of fault detection and correction algorithms that can be implemented in thermostats with two-way OpenAPIs. It is written in the Python language. The algorithms aim to detect the most common and impactful efficiency problems associated with thermostat setpoints - overly aggressive heating or cooling setpoints, incorrect schedules/setbacks, and overly narrow deadbands. These algorithms can automatically detect faults, and implement associated corrective actions to bring the system back to a state of efficient operation. The algorithms can run remotely in the cloud, and directly implemented by connected thermostat manufacturers, or by third party service providers. The software enables a lightweight cost-effective energy management strategy for HVAC systems. The solution is specially viable for small and medium sized commercial buildings, where a full scale building automation system and fault detection and diagnostic tools are often unavailable.

Granderson, Jessica↗

Proving the Business Case for Building Analytics

As building monitoring becomes more common, facilities teams are faced with an overwhelming amount of data. These data do not typically lead to insights or corrective actions unless they are stored, organized, analyzed, and prioritized in automated ways. Buildings are full of energy savings potential that can be uncovered with the right analysis. With analytic software applied to everyday building operations, owners are using data to their advantage and realizing cost savings through improved energy management.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Building an EPA Class VI Permit Application

Summary To accelerate the commercialization of carbon capture and storage (CCS), the US Department of Energy (US DOE) is building on decades of characterization efforts and pilot-scale projects through their CarbonSAFE program. Administered through their National Energy Technology Laboratory, this program seeks to bring fully integrated projects to the sector that can store more than 50 million tonnes of CO2 over a 30-year period. The program, which was enacted before the enhancement of Internal Revenue Code Section 45Q, is in the capture assessment, characterization, and permitting phase. The objectives of this paper are to discuss (a) the injection permitting requirements of the CarbonSAFE projects; (b) information gathering in support of the permit; (c) the timelines of field development and permit-related activities; (d) the major technical components of the field development plan; and (e) early feedback from the regulators toward acceptance of the permit. In Mississippi, more than 30,000 acres have been characterized by six deep characterization wells, a deep groundwater well, and 92 line miles of 2D seismic as part of the CarbonSAFE Project ECO2S. During the acquisition of seismic data, all receiver lines were live, which resulted in the generation of a pseudo-3D seismic design. The incorporation of a 3D seismic survey was not included as part of this project due to logistical difficulties presented by the undulating, wooded surface terrain. A suite of openhole geophysical logs was taken from each well, allowing for a detailed interpretation of prospective storage reservoirs and confining intervals to complement the analysis carried out on the 290 ft of a whole core that was cut through the prospective confining zone and storage reservoir. The detailed geologic and reservoir data were assembled and entered into a 3D model to assess the injection capacity and the area of review (AoR). This information fed into the detailed corrective action, monitoring, testing, and postinjection site care (PISC) modeling. The results have been exceptional. The geologic assessment has revealed three primary storage targets, ranging in depth from 3,500 ft to 6,000 ft. These storage reservoirs net 1,300 ft of sandstone, with mean porosity and permeability of 29% and 3.6 darcies, respectively. Together, these reservoirs have storage capacities that may exceed 20 million tonnes per square mile, making this a gigatonne prospect. Forward modeling of the project resulted in an AoR of 16 sq miles, injecting about 8000 t/d, for 30 years, via two deep injection wells. The excellent confining characteristics of the caprock, relatively simple geologic structure, and lack of historical well drilling activity in this area provide excellent containment of the injected CO2. Based on this work, the project has proposed 20 years of PISC. To date, only two US CO2 injection permits have been granted. These projects relied on a singular capture point feeding a singular sequestration point (source to sink), and considerations have not been made to garner CO2 emissions from other industrial sources. The Kemper County Storage Complex is a first-of-its-kind storage hub concept that looks to develop an area capable of storing significant quantities of CO2 from the region. Also, this work will show how characterization efforts, geological and numerical modeling efforts, and plan development were constructed in support of permit and incentives acceptance.

Energy & Fuels↗

Argonne National Laboratory Site Environmental Report (CY2019)

This report discusses the status and the accomplishments of the environmental protection program at Argonne National Laboratory for calendar year 2019. The status of Argonne environmental protection activities with respect to compliance with the various laws and regulations is discussed, along with environmental management, sustainability efforts, environmental corrective actions, and habitat restoration. To evaluate the effects of Argonne operations on the environment, samples of environmental media collected on the site, at the site boundary, and off the Argonne site were analyzed and compared with applicable guidelines and standards. A variety of radionuclides were measured in air, surface water, groundwater, and bottom sediment samples. In addition, chemical constituents in surface water, groundwater, and wastewater were analyzed. External penetrating radiation doses were measured, and the potential for radiation exposure to off-site population groups was estimated. Results are interpreted with respect to the origin of the radioactive and chemical substances (i.e., natural, Argonne, and other) and are compared with applicable standards intended to protect human health and the environment. A U.S. Department of Energy (DOE) dose calculation methodology, based on International Commission on Radiological Protection (ICRP) recommendations and the U.S. Environmental Protection Agency’s (EPA) CAP-88 Version 4 computer code, was used in preparing this report.

54 ENVIRONMENTAL SCIENCES↗

NTS-SS-SNL-NMSITE-2017-0004,"Contamination Monitor Left in Service After Inadequate Calibration" Causes Not Fully Addressed (ES&H Causal Analysis Report)

Sandia National Laboratories Radiation Protection department did not successfully address the causes leading to the issue NTS-SS-SNL-NMSITE-2017-0004, “Contamination Monitor Left in Service After Inadequate Calibration”, nor identify through the verification and validation process that corrective actions were not fully implemented and effective at addressing the issue(s). This report is the third causal in four years associated with the iPCM12 instrument and the Radiation Protection Instrumentation (RPI) organization within Radiation Protection (00628).

61 RADIATION PROTECTION AND DOSIMETRY↗

NTS-SS-SNL-NMSITE-2017-0004 "Contamination Monitor Left in Service After Inadequate Calibration" Causes Not Fully Addressed (Causal Analysis Report)

On June 5th, 2020 Sandia National Laboratories signed and recommended for closure the evidence package for the Noncompliance Tracking System NTS—SS-SNL-NMSITE-2017-0004, Contamination Monitor Left in Service After Inadequate Calibration. On July 16th, 2020 the Sandia Field Office sent a follow-up question list to the Radiation Protection Instrumentation Program Lead to clarify some points while reviewing the evidence package. The follow-up questions readily identified deficiencies with all three calibrations of the iPCM12 systems. On July 30th, 2020 Radiation Protection hosted a meeting to better understand the exact nature of the concerns, determine if the iPCM12 machines were out of calibration and therefore would have to be taken out of service. One result of this meeting was to determine if SNL could withdraw the evidence package. SNL transmitted a letter on August 26th, 2020 recalling the evidence package and committed to performing a thorough causal analysis and invoke the required issues management processes to ensure that corrective actions are sustained.

54 ENVIRONMENTAL SCIENCES↗

Summary of Assessments Performed in FY 21 by SNL QA POC for FY 20 SNL NFCSC Milestone Deliverables

The Sandia National Laboratories (SNL) staff is meeting the requirements of the Nuclear Fuel Cycle and Supply Chain (NFCSC) Quality Assurance Program Document (QAPD). Each of the 5 NFCSC FY 20 packages for SNL were reviewed. None of the 5 packages had incorrect QRL categories. No major corrective actions are assigned. Additional and minor PICS:NE checkbox errors may exist, but none were identified in this assessment. Training is now also geared to encourage WPMs to take credit for optional technical reviews by considering setting the QRL level to 3. This is because when the level is set to 4, the PICS:NE system does not provide fields for review information. Finally, training in the NFCSC QAPD has been delivered as always to WPMs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Displacement driven balancing of a diamond turning machine flycutter

The spindle balancing operation is critical to the performance of precision lathes and should be conducted anytime the configuration of the spindle or its tooling is modified such that an unbalanced condition may occur. Within the machine tool community, accelerometers are typically used as the feedback device during the balancing operation. At Lawrence Livermore National Laboratory (LLNL), we have nearly 40 years of history using displacement sensors, such as capacitance gauges, in place of accelerometers when balancing precision spindles. The process of balancing a precision machine spindle using displacement sensors is presented in the context of two work examples. In this case, the details of the one-dimensional balancing operation performed after replacing a flycutter on the spindles of two unique large optic diamond turning machines is discussed. The pros and cons of accelerometer driven balancing and displacement driven balancing are also presented. In the accelerometer context, the level of balance achieved for our work example is less than 100 micro-g or a total indicator reading (TIR) of 1.6 µm. The process of balancing has been enhanced over the years as advances have been made in software, data acquisition systems, and instrumentation. The balancing system is described including details about instrumentation, set-up, how phase and spindle structure stiffness is calculated, and how the LLNL developed software that guides the user through the process by suggesting corrective action.

42 ENGINEERING↗

Argonne National Laboratory Site Environmental Report (CY2020)

This report discusses the status and the accomplishments of the environmental protection program at Argonne National Laboratory for calendar year 2020. The status of Argonne environmental protection activities with respect to compliance with the various laws and regulations is discussed, along with environmental management, sustainability efforts, environmental corrective actions, and habitat restoration. To evaluate the effects of Argonne operations on the environment, samples of environmental media collected on the site, at the site boundary, and off the Argonne site were analyzed and compared with applicable guidelines and standards. A variety of radionuclides were measured in air, surface water, groundwater, and bottom sediment samples. In addition, chemical constituents in surface water, groundwater, and wastewater were analyzed. External penetrating radiation doses were measured, and the potential for radiation exposure to off site population groups was estimated. Results are interpreted with respect to the origin of the radioactive and chemical substances (i.e., natural, Argonne, and other) and are compared with applicable standards intended to protect human health and the environment. A U.S. Department of Energy (DOE) dose calculation methodology, based on International Commission on Radiological Protection (ICRP) recommendations and the U.S. Environmental Protection Agency’s (EPA) CAP 88 Version 4.1 computer code, was used in preparing this report.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Photographic Mitigation Documentation Related to the Engine Assembly and Disassembly Facility, Area 25, Nevada National Security Site, Nye County, Nevada

This letter report provides documentation in partial fulfillment of the mitigation of adverse effects to the Engine Maintenance Assembly and Disassembly (E-MAD) facility, a major component of the Nuclear Rocket Development Station (NRDS) Historic District located in Area 25 of the Nevada National Security Site (NNSS). Construction of the E-MAD facility began in 1962 for the purpose of disassembling and maintaining nuclear-powered rocket engines. Once the building was complete in 1967, the E-MAD facility remained in continuous operation until the nuclear rocket program was terminated in 1973. The mothballed facility was repurposed in 1977 for spent nuclear fuel handling and packaging activities. By the mid-1980s, all activities at the E-MAD facility had ceased (Reno et al. 2019). This submission is intended to comply with Stipulation III.D.1 of the Memorandum of Agreement DE-GM58-20NA25534 between the U.S. Department of Energy and the Nevada State Historic Preservation Officer Regarding Corrective Action Activities and Demolition of the Engine Maintenance Assembly and Disassembly Facility and the Test Cell C Historic District, Major Components of the Nuclear Rocket Development Station Historic District Located in Area 25 at the Nevada National Security Site Nye County (hereafter referred to as the MOA). Stipulation III.D.1 states the U.S. Department of Energy (DOE) will submit the existing supplementary collection of the large-format, black-and-white photographic prints taken during the 1996 Historic American Engineering Record (HAER) documentation of the E-MAD facility to the Nuclear Testing Archive (NTA), located on the second floor of the Rogers Building at Desert Research Institute (DRI) in Las Vegas, Nevada.

54 ENVIRONMENTAL SCIENCES↗

Effects of Intrusive Confining Units on Groundwater Flow at Pahute Mesa, Nevada National Security Site

Geological, geophysical, hydrogeological, and hydrological evidence indicates that feeder dikes to rhyolitic lava flows may play a role as confining units in the groundwater flow system underlying the Pahute Mesa (PM) area of underground nuclear testing at the Nevada National Security Site (NNSS) (Figure 1). Of geological significance, the PM testing area is largely situated within the Silent Canyon caldera complex (SCCC), which includes both tuffs and lavas that were fed by (and are connected to) intrusive rock units such as feeder dikes prior to and during volcanic eruptions (Orkild et al., 1968; Byers et al., 1976a). Groundwater modeling results presented in this report support extension of “pool-dam” and “breach scenario” concepts presented in Jackson and Fenelon (2018) and Jackson et al. (2021) to low-permeability intrusive confining units (ICUs) such as feeder dikes that are expected to dissect and ring silicic calderas. As laterally extensive, steeply-dipping, and sub-parallel planar structures, ICUs may further compartmentalize groundwater flow in some areas of the volcanic aquifer system at PM. ICUs may explain unusually high horizontal hydraulic gradient southwest of Cheshire. Breaching of an ICU within which the Cheshire test was emplaced may explain changes in water levels before and after the Cheshire test was detonated in the U-20n emplacement hole on 2/14/76 (USDOE, 2015b). This analysis of the effects of ICUs on groundwater flow at PM addresses a need to evaluate uncertainty in the conceptual model or structural aspects of hydrologic source term (HST) or corrective action unit (CAU) models for groundwater flow and contaminant transport (FFACO, 1996, as amended). At Cheshire and possibly other test locations at PM, downgradient extent of radionuclide contamination may be overpredicted by not including the confining effects of ICUs. On the other hand, contaminant extent may be underpredicted by not considering transient flow effects and/or the re-equilibrated flow field caused by breaching of an ICU by an underground nuclear test. Near Cheshire, the effects of ICUs may be most apparent and impactful to the groundwater flow system at PM because of an unusual combination of thickness, extent, and frequency of dikes transecting the saturated CHLFA4 aquifer and feeding into the overlying unsaturated rhyolite lava of Windy Wash. Chapters 2, 3, and 4 present geological, geophysical, hydrogeological, and hydrological evidence for ICUs at PM. Chapters 5 and 6 examine effects of ICUs on groundwater flow including analysis by groundwater modeling.

54 ENVIRONMENTAL SCIENCES↗

Argonne National Laboratory Site Environmental Report for Calendar Year 2021

This report discusses the status and the accomplishments of the environmental protection program at Argonne National Laboratory for calendar year 2021. The status of Argonne environmental protection activities with respect to compliance with the various laws and regulations is discussed, along with environmental management, sustainability efforts, environmental corrective actions, and habitat restoration. To evaluate the effects of Argonne operations on the environment, samples of environmental media collected on the site, at the site boundary, and off the Argonne site were analyzed and compared with applicable guidelines and standards. A variety of radionuclides were measured in air, surface water, groundwater, and bottom sediment samples. In addition, chemical constituents in surface water, groundwater, and wastewater were analyzed. External penetrating radiation doses were measured, and the potential for radiation exposure to off site population groups was estimated. Results are interpreted with respect to the origin of the radioactive and chemical substances (i.e., natural, Argonne, and other) and are compared with applicable standards intended to protect human health and the environment. A U.S. Department of Energy (DOE) dose calculation methodology, based on International Commission on Radiological Protection (ICRP) recommendations and the U.S. Environmental Protection Agency’s (EPA) CAP 88 Version 4.1 computer code, was used in preparing this report.

54 ENVIRONMENTAL SCIENCES↗

Calendar Year 2021 Post-Closure Monitoring Letter Report (Rev. 1)

This letter serves as the annual post-closure letter for Corrective Action Unit (CAU) 97, Yucca Flat/Climax Mine (YF/CM); CAU 98, Frenchman Flat (FF); and CAU 99, Rainier Mesa/Shoshone Mountain (RM/SM) for calendar year (CY) 2021. This letter will discuss the post-closure monitoring activities that occurred during CY 2021, identify any triggers reached, and summarize water usage on the Nevada National Security Site (NNSS) and surrounding hydrographic basins at the three CAUs.

54 ENVIRONMENTAL SCIENCES↗

Argonne National Laboratory Site Environmental Report for Calendar Year 2022

This report discusses the status and the accomplishments of the environmental protection program at Argonne National Laboratory for calendar year 2022. The status of Argonne environmental protection activities with respect to compliance with the various laws and regulations is discussed, along with environmental management, sustainability efforts, environmental corrective actions, and habitat restoration. To evaluate the effects of Argonne operations on the environment, samples of environmental media collected on the site, at the site boundary, and off the Argonne site were analyzed and compared with applicable guidelines and standards. A variety of radionuclides were measured in air, surface water, groundwater, and bottom sediment samples. In addition, chemical constituents in surface water, groundwater, and wastewater were analyzed. External penetrating radiation doses were measured, and the potential for radiation exposure to off site population groups was estimated. Results are interpreted with respect to the origin of the radioactive and chemical substances (i.e., natural, Argonne, and other) and are compared with applicable standards intended to protect human health and the environment. A U.S. Department of Energy (DOE) dose calculation methodology, based on International Commission on Radiological Protection (ICRP) recommendations and the U.S. Environmental Protection Agency’s (EPA) CAP 88 Version 4.1 computer code, was used in preparing this report.

54 ENVIRONMENTAL SCIENCES↗

Calendar Year 2022 Post-Closure Monitoring Letter Report (Rev. 1)

This letter serves as the annual post-closure letter for Corrective Action Unit 98, Frenchman Flat; CAU 97, Yucca Flat/Climax Mine; and CAU 99, Rainier Mesa/Shoshone Mountain for calendar year 2022. This letter will discuss the post-closure monitoring activities that occurred during CY 2022, identify any triggers reached, and summarize water usage on the Nevada National Security Site (NNSS) and surrounding hydrographic basins at the three CAUs.

54 ENVIRONMENTAL SCIENCES↗

Process Anomaly Detection for Sparsely Labeled Events in Nuclear Power Plants

An essential aspect of online monitoring, subtle anomaly detection increases the detection lead time for equipment failure and enables a nuclear power plant (NPP) to mitigate unexpected partial or full outages, resulting in significant cost saving to the plant. Once an anomaly is detected by plant staff, its cause and severity are investigated. Because the vast majority of anomalies require some level of investigation, including some that require time-consuming examination, before they are passed over to the engineering organization for further analysis, plants are often equipped with tools to assist the staff in performing anomaly detection. Those tools operate as a black box and are often based on statistical methods that establish sensor correlations using preconfigured mathematical models and flag correlation deviations as anomalies. Due to the number of anomalies detected at a given NPP on a daily basis, a significant number of flagged anomalies usually await examination for days or weeks. A primary cause of this backlog is that the methods used by the tools generate many false positives. Though this is usually attributed to oversensitive model settings due to very narrow normal operation bands, it can also be associated with the model development being inadequate for the process being monitored, or with missing model inputs that could have explained misclassified positives. The performance of anomaly detection tools impacts their plant acceptance and utilization, especially when the effort to address false positives generated by the tool depletes the value or cost saved by using that tool. Thus, means to advance anomaly detection performance have been investigated by the Department of Energy’s Light Water Reactor Sustainability program. Previous and ongoing efforts have targeted unsupervised machine-learning (ML) methods, which do not require the labeling of any data fed into the ML model. By contrast, in supervised anomaly detection methods, every data point is labeled as either a normal or abnormal process condition, and the model is trained to replicate the classification process. Supervised methods usually outperform unsupervised methods, due to the added value in differentiating normal from anomalous states of the monitored process. An NPP’s corrective action program requires it to track and document, via a dedicated report, the resolution of any issues that occur within the plant. Once created, each report is reviewed by a plant screening committee, and several classifications and decisions are made. Recently, a collaborating NPP developed an artificial intelligence and ML-based classifier to categorize a condition report (CR) into classes that can serve to label the data as normal or anomalous. Applying CRs as labels represents a semi-supervised use case. Semi-supervised ML assumes that labels exist for some data points (i.e., labeled anomalies, in this case) but not for the rest. In this effort, semi-supervised ML methods were used to fuse data from CRs with anomaly detection methods in order to test the hypothesis that partially labeled anomalies would improve the accuracy of the anomaly detection methods. Specifically, two methods were used. The first is the deep Semi-supervised Anomaly Detection (deep SAD) method, which can handle labels ranging from fully unsupervised to fully supervised cases. The second is a newly designed ML method developed specifically for this effort and referred to as the high-order feature (HOF)-based method. To evaluate these two methods in controlled environments, synthetic data generators were developed and used. The first datasets used a spring-mass-damper (SMD) system simulator commonly found in mechanical engineering references. This was used to create two use cases: a one- and a three-mass system. Anomalies were introduced by changing the spring and damper coefficients while the system was actuated by random forces. The second datasets used the commercial Dymola-Modelica software to build a simplified nuclear reactor model. Anomalies were added in the form of corrupted sensor readings and/or control commands. The deep SAD method was tested using the SMD system, while the HOF method was tested using both datasets. Application of the deep SAD semi-supervised ML method demonstrated that labels can generate increased confidence in detecting true anomalies. This helped increase the number of true positives and decrease the number of false negatives—something that would aid in addressing the backlog of possible anomalies. Application of the HOF method demonstrated that labels can aid in down selecting from a candidate set of features to a more optimal subset in order to better differentiate between normal and anomalous conditions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗