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NASA NTRS2004

Conducting Closed Habitation Experiments: Experience from the Lunar Mars Life Support Test Project

The Lunar-Mars Life Support Test Project (LMLSTP) was conducted from 1995 through 1997 at the National Aeronautics and Space Administration s (NASA) Johnson Space Center (JSC) to demonstrate increasingly longer duration operation of integrated, closed-loop life support systems that employed biological and physicochemical techniques for water recycling, waste processing, air revitalization, thermal control, and food production. An analog environment for long-duration human space travel, the conditions of isolation and confinement also enabled studies of human factors, medical sciences (both physiology and psychology) and crew training. Four tests were conducted, Phases I, II, IIa and III, with durations of 15, 30,60 and 91 days, respectively. The first phase focused on biological air regeneration, using wheat to generate enough oxygen for one experimental subject. The systems demonstrated in the later phases were increasingly complex and interdependent, and provided life support for four crew members. The tests were conducted using two human-rated, atmospherically-closed test chambers, the Variable Pressure Growth Chamber (VPGC) and the Integrated Life Support Systems Test Facility (ILSSTF). Systems included test articles (the life support hardware under evaluation), human accommodations (living quarters, kitchen, exercise equipment, etc.) and facility systems (emergency matrix system, power, cooling, etc.). The test team was managed by a lead engineer and a test director, and included test article engineers responsible for specific systems, subsystems or test articles, test conductors, facility engineers, chamber operators and engineering technicians, medical and safety officers, and science experimenters. A crew selection committee, comprised of psychologists, engineers and managers involved in the test, evaluated male and female volunteers who applied to be test subjects. Selection was based on the skills mix anticipated for each particular test, and utilized information from psychological and medical testing, data on the knowledge, experience and skills of the applicants, and team building exercises. The design, development, buildup and operation of test hardware and documentation followed the established NASA processes and requirements for test buildup and operation.

Barta, Daniel J.↗

NASA NTRS2006

Electrical Arc Ignition Testing of Spacesuit Materials

A viewgraph presentation on electrical arc ignition testing of spacesuit materials is shown. The topics include: 1) Background; 2) Test Objectives; 3) Test Sample Materials; 4) Test Methods; 5) Scratch Test Objectives; 6) Cotton Scratch Test Video; 7) Scratch Test Results; 8) Entire Date Plot; 9) Closeup Data Plot; 10) Scratch Test Problems; 11) Poke Test Objectives; 12) Poke Test Results; 13) Poke Test Problems; 14) Wire-break Test Objectives; 15) Cotton Wire-Break Test Video; 16) High Speed Cotton Wire-break Test Video; 17) Typical Data Plot; 18) Closeup Data Plot; 19) Wire-break Test Results; 20) Wire-break Tests vs. Scratch Tests; 21) Urethane-coated Nylon; and 22) Moleskin.

Smith, Sarah↗

NASA NTRS2011

GOES Type III Loop Heat Pipe Life Test Results

The GOES Type III Loop Heat Pipe (LHP) was built as a life test unit for the loop heat pipes on the GOES N-Q series satellites. This propylene LHP was built by Dynatherm Corporation in 2000 and tested continuously for approximately 14 months. It was then put into storage for 3 years. Following the storage period, the LHP was tested at Swales Aerospace to verify that the loop performance hadn t changed. Most test results were consistent with earlier results. At the conclusion of testing at Swales, the LHP was transferred to NASA/GSFC for continued periodic testing. The LHP has been set up for testing in the Thermal Lab at GSFC since 2006. A group of tests consisting of start-ups, power cycles, and a heat transport limit test have been performed every six to nine months since March 2006. Tests results have shown no change in the loop performance over the five years of testing. This presentation will discuss the test hardware, test set-up, and tests performed. Test results to be presented include sample plots from individual tests, along with conductance measurements for all tests performed.

Ottenstein, Laura↗

NASA NTRS2014

Low-Cost, Class D Testing of Spacecraft Photovoltaic Systems Can Reduce Risk

The end-to-end verification of a spacecraft photovoltaic power generation system requires light! Specifically, the standard practice for doing so is the Large Area Pulsed Solar Simulation (LAPSS). A LAPSS test can characterize a photovoltaic system's efficiency via its response to rapidly applied impulses of simulated sunlight. However, a Class D program on a constrained budget and schedule may not have the resources to ship an entire satellite for a LAPSS test alone. Such was the case with the Lunar Atmospheric and Dust Environment Explorer (LADEE) program, which was also averse to the risk of hardware damage during shipment. When the Electrical Power System (EPS) team was denied a spacecraft-level LAPSS test, the lack of an end-to-end power generation test elevated to a project-level technical risk. The team pulled together very limited resources to not only eliminate the risk, but build a process to monitor the health of the system through mission operations. We discuss a process for performing a low-cost, end-to-end test of the LADEE photovoltaic system. The approach combines system-level functional test, panel-level performance results, and periodic inspection (and repair) up until launch. Following launch, mission operations tools are utilized to assess system performance based on a scant amount of data. The process starts in manufacturing at the subcontractor. The panel manufacturer provides functional test and LAPSS data on each individual panel. We apply an initial assumption that the per-panel performance is sufficient to meet the power generation requirements. The manufacturer's data is also carried as the performance allocation for each panel during EPS system modeling and initial mission operations. During integration and test, a high-power, professional theater lamp system provides simulated sunlight to each panel on the spacecraft, thereby permitting a true end-to-end system test. A passing test results in a step response to nearly full-rated current at the appropriate solar array switch in the power system. A metal-halide bulb, infrared imagers, and onboard spacecraft measurements are utilized to minimize risk of thermal damage during test. Data is provided to support test results for both passing and marginal panels. Prior to encapsulation in the launch vehicle, each panel is inspected for damage by the panel manufacturer. Cracked cells or other damage is amended on-site. Because the photovoltaic test system is inexpensive and portable, each repaired panel can be re-verified immediately. Post-launch, the photovoltaic system is again characterized for per-panel deviations from the manufacturer's performance test. This proved especially tricky as the LADEE spacecraft performs only one current measurement on the entire array. The algorithm for Matlab tools to assess panel performance based on spacecraft attitude is discussed. While not as precise and comprehensive as LAPSS, the LADEE approach leverages minimal resources into an ongoing assessment program that can be applied through numerous stages of the mission. The project takes a true Class D approach in assessing the technical value of a spacecraft level performance test versus the programmatic risk of shipping the spacecraft to another facility. The resources required are a fraction of that for a LAPSS test, and is easy to repeat. Further, the test equipment can be handed down to future projects without building an on-site facility.

photovoltaic↗

NASA NTRS2015

A Vehicle Management End-to-End Testing and Analysis Platform for Validation of Mission and Fault Management Algorithms to Reduce Risk for NASAs Space Launch System

The engineering development of the National Aeronautics and Space Administration's (NASA) new Space Launch System (SLS) requires cross discipline teams with extensive knowledge of launch vehicle subsystems, information theory, and autonomous algorithms dealing with all operations from pre-launch through on orbit operations. The nominal and off-nominal characteristics of SLS's elements and subsystems must be understood and matched with the autonomous algorithm monitoring and mitigation capabilities for accurate control and response to abnormal conditions throughout all vehicle mission flight phases, including precipitating safing actions and crew aborts. This presents a large and complex systems engineering challenge, which is being addressed in part by focusing on the specific subsystems involved in the handling of off-nominal mission and fault tolerance with response management. Using traditional model-based system and software engineering design principles from the Unified Modeling Language (UML) and Systems Modeling Language (SysML), the Mission and Fault Management (M&FM) algorithms for the vehicle are crafted and vetted in Integrated Development Teams (IDTs) composed of multiple development disciplines such as Systems Engineering (SE), Flight Software (FSW), Safety and Mission Assurance (S&MA) and the major subsystems and vehicle elements such as Main Propulsion Systems (MPS), boosters, avionics, Guidance, Navigation, and Control (GNC), Thrust Vector Control (TVC), and liquid engines. These model-based algorithms and their development lifecycle from inception through FSW certification are an important focus of SLS's development effort to further ensure reliable detection and response to off-nominal vehicle states during all phases of vehicle operation from pre-launch through end of flight. To test and validate these M&FM algorithms a dedicated test-bed was developed for full Vehicle Management End-to-End Testing (VMET). For addressing fault management (FM) early in the development lifecycle for the SLS program, NASA formed the M&FM team as part of the Integrated Systems Health Management and Automation Branch under the Spacecraft Vehicle Systems Department at the Marshall Space Flight Center (MSFC). To support the development of the FM algorithms, the VMET developed by the M&FM team provides the ability to integrate the algorithms, perform test cases, and integrate vendor-supplied physics-based launch vehicle (LV) subsystem models. Additionally, the team has developed processes for implementing and validating the M&FM algorithms for concept validation and risk reduction. The flexibility of the VMET capabilities enables thorough testing of the M&FM algorithms by providing configurable suites of both nominal and off-nominal test cases to validate the developed algorithms utilizing actual subsystem models such as MPS, GNC, and others. One of the principal functions of VMET is to validate the M&FM algorithms and substantiate them with performance baselines for each of the target vehicle subsystems in an independent platform exterior to the flight software test and validation processes. In any software development process there is inherent risk in the interpretation and implementation of concepts from requirements and test cases into flight software compounded with potential human errors throughout the development and regression testing lifecycle. Risk reduction is addressed by the M&FM group but in particular by the Analysis Team working with other organizations such as S&MA, Structures and Environments, GNC, Orion, Crew Office, Flight Operations, and Ground Operations by assessing performance of the M&FM algorithms in terms of their ability to reduce Loss of Mission (LOM) and Loss of Crew (LOC) probabilities. In addition, through state machine and diagnostic modeling, analysis efforts investigate a broader suite of failure effects and associated detection and responses to be tested in VMET to ensure reliable failure detection, and confirm responses do not create additional risks or cause undesired states through interactive dynamic effects with other algorithms and systems. VMET further contributes to risk reduction by prototyping and exercising the M&FM algorithms early in their implementation and without any inherent hindrances such as meeting FSW processor scheduling constraints due to their target platform - the ARINC 6535-partitioned Operating System, resource limitations, and other factors related to integration with other subsystems not directly involved with M&FM such as telemetry packing and processing. The baseline plan for use of VMET encompasses testing the original M&FM algorithms coded in the same C++ language and state machine architectural concepts as that used by FSW. This enables the development of performance standards and test cases to characterize the M&FM algorithms and sets a benchmark from which to measure their effectiveness and performance in the exterior FSW development and test processes. This paper is outlined in a systematic fashion analogous to a lifecycle process flow for engineering development of algorithms into software and testing. Section I describes the NASA SLS M&FM context, presenting the current infrastructure, leading principles, methods, and participants. Section II defines the testing philosophy of the M&FM algorithms as related to VMET followed by section III, which presents the modeling methods of the algorithms to be tested and validated in VMET. Its details are then further presented in section IV followed by Section V presenting integration, test status, and state analysis. Finally, section VI addresses the summary and forward directions followed by the appendices presenting relevant information on terminology and documentation.

Trevino, Luis↗

NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Human-in-the-Loop (HITL) Testing

The space suit Portable Life Support System (PLSS) 2.0 represents the second integrated prototype developed and tested to mature a design that uses advanced technologies to reduce consumables, improve robustness, and provide additional capabilities over the current state of the art. PLSS 2.0 was developed in 2012, with extensive functional evaluations and system performance testing through mid-2014. In late 2014, PLSS 2.0 was integrated with the Mark III space suit in an ambient laboratory environment to facilitate manned testing, designated PLSS 2.0 Human-in-the-Loop (HITL) testing, in which the PLSS prototype performed the primary life support functions, including suit pressure regulation, ventilation, carbon dioxide control, and cooling of the test subject and PLSS avionics. The intent of this testing was to obtain subjective test subject feedback regarding qualitative aspects of PLSS 2.0 performance such as thermal comfort, sounds, smells, and suit pressure fluctuations due to the cycling carbon dioxide removal system, as well as to collect PLSS performance data over a range of human metabolic rates from 500-3000 Btu/hr. Between October 27 and December 18, 2014, nineteen two-hour simulated EVA test points were conducted in which suited test subjects walked on a treadmill to achieve a target metabolic rate. Six test subjects simulated nominal and emergency EVA conditions with varied test parameters including metabolic rate profile, carbon dioxide removal control mode, cooling water temperature, and Liquid Cooling and Ventilation Garment (state of the art or prototype). The nineteen test points achieved more than 60 hours of test time, with 36 hours accounting for simulated EVA time. The PLSS 2.0 test article performed nominally throughout the test series, confirming design intentions for the advanced PLSS. Test subjects' subjective feedback provided valuable insight into thermal comfort and perceptions of suit pressure fluctuations that will influence future advanced PLSS design and testing strategies.

Watts, Carly↗

NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design which is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data to define set-points for control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out from 3/20/13 - 3/15/14 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Watts, Carly↗

NASA NTRS2013

Lessons Learned During Instrument Testing for the Thermal Infrared Sensor (TIRS)

The Themal InfraRed Sensor (TIRS) instrument, set to launch on the Landsat Data Continuity Mission in 2013, features a passively cooled telescope and IR detectors which are actively cooled by a two stage cryocooler. In order to proceed to the instrument level test campaign, at least one full functional test was required, necessitating a thermal vacuum test to sufficiently cool the detectors and demonstrate performance. This was fairly unique in that this test occurred before the Pre Environmental Review, but yielded significant knowledge gains before the planned instrument level test. During the pre-PER test, numerous discrepancies were found between the model and the actual hardware, which were revealed by poor correlation between model predictions and test data. With the inclusion of pseudo-balance points, the test also provided an opportunity to perform a pre-correlation to test data prior to the instrument level test campaign. Various lessons were learned during this test related to modeling and design of both the flight hardware and the Ground Support Equipment and test setup. The lessons learned in the pre-PER test resulted in a better test setup for the nstrument level test and the completion of the final instrument model correlation in a shorter period of time. Upon completion of the correlation, the flight predictions were generated including the full suite of off-nominal cases, including some new cases defined by the spacecraft. For some of these ·new cases, some components now revealed limit exceedances, in particular for a portion of the hardware that could not be tested due to its size and chamber limitations.. Further lessons were learned during the completion of flight predictions. With a correlated detalled instrument model, significant efforts were made to generate a reduced model suitable for observatory level analyses. This proved a major effort both to generate an appropriate network as well as to convert to the final model to the required format and yielded additional lessons learned. In spite of all the challenges encountered by TIRS, the instrument was successfully delivered to the spacecraft and will soon be tested at observatory level in preparation for a successful mission launch.

Peabody, Hume L.↗

NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design. This advanced PLSS is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data, define set-points, evaluate control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out in 2013 and 2014 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Anchondo, Ian↗

NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Human-in-the-Loop (HITL) Testing

Watts, Carly↗

DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2012

Analysis of Phenix end-of-life natural convection test with the MARS-LMR code

The end-of-life test of Phenix reactor performed by the CEA provided an opportunity to have reliable and valuable test data for the validation and verification of a SFR system analysis code. KAERI joined this international program for the analysis of Phenix end-of-life natural circulation test coordinated by the IAEA from 2008. The main objectives of this study were to evaluate the capability of existing SFR system analysis code MARS-LMR and to identify any limitation of the code. The analysis was performed in three stages: pre-test analysis, blind posttest analysis, and final post-test analysis. In the pre-test analysis, the design conditions provided by the CEA were used to obtain a prediction of the test. The blind post-test analysis was based on the test conditions measured during the tests but the test results were not provided from the CEA. The final post-test analysis was performed to predict the test results as accurate as possible by improving the previous modeling of the test. Based on the pre-test analysis and blind test analysis, the modeling for heat structures in the hot pool and cold pool, steel structures in the core, heat loss from roof and vessel, and the flow path at core outlet were reinforced in the final analysis. The results of the final post-test analysis could be characterized into three different phases. In the early phase, the MARS-LMR simulated the heat-up process correctly due to the enhanced heat structure modeling. In the mid phase before the opening of SG casing, the code reproduced the decrease of core outlet temperature successfully. Finally, in the later phase the increase of heat removal by the opening of the SG opening was well predicted with the MARS-LMR code. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2012

Properties Important to Mixing for WTP Large Scale Integrated Testing

Large Scale Integrated Testing (LSIT) is being planned by Bechtel National, Inc. to address uncertainties in the full scale mixing performance of the Hanford Waste Treatment and Immobilization Plant (WTP). Testing will use simulated waste rather than actual Hanford waste. Therefore, the use of suitable simulants is critical to achieving the goals of the test program. External review boards have raised questions regarding the overall representativeness of simulants used in previous mixing tests. Accordingly, WTP requested the Savannah River National Laboratory (SRNL) to assist with development of simulants for use in LSIT. Among the first tasks assigned to SRNL was to develop a list of waste properties that matter to pulse-jet mixer (PJM) mixing of WTP tanks. This report satisfies Commitment 5.2.3.1 of the Department of Energy Implementation Plan for Defense Nuclear Facilities Safety Board Recommendation 2010-2: physical properties important to mixing and scaling. In support of waste simulant development, the following two objectives are the focus of this report: (1) Assess physical and chemical properties important to the testing and development of mixing scaling relationships; (2) Identify the governing properties and associated ranges for LSIT to achieve the Newtonian and non-Newtonian test objectives. This includes the properties to support testing of sampling and heel management systems. The test objectives for LSIT relate to transfer and pump out of solid particles, prototypic integrated operations, sparger operation, PJM controllability, vessel level/density measurement accuracy, sampling, heel management, PJM restart, design and safety margin, Computational Fluid Dynamics (CFD) Verification and Validation (V and V) and comparison, performance testing and scaling, and high temperature operation. The slurry properties that are most important to Performance Testing and Scaling depend on the test objective and rheological classification of the slurry (i.e., Newtonian or non-Newtonian). The most important properties for testing with Newtonian slurries are the Archimedes number distribution and the particle concentration. For some test objectives, the shear strength is important. In the testing to collect data for CFD V and V and CFD comparison, the liquid density and liquid viscosity are important. In the high temperature testing, the liquid density and liquid viscosity are important. The Archimedes number distribution combines effects of particle size distribution, solid-liquid density difference, and kinematic viscosity. The most important properties for testing with non-Newtonian slurries are the slurry yield stress, the slurry consistency, and the shear strength. The solid-liquid density difference and the particle size are also important. It is also important to match multiple properties within the same simulant to achieve behavior representative of the waste. Other properties such as particle shape, concentration, surface charge, and size distribution breadth, as well as slurry cohesiveness and adhesiveness, liquid pH and ionic strength also influence the simulant properties either directly or through other physical properties such as yield stress.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Integrated Data Collection Analysis (IDCA) Program - SSST Testing Methods

The Integrated Data Collection Analysis (IDCA) program is conducting a proficiency study for Small- Scale Safety and Thermal (SSST) testing of homemade explosives (HMEs). Described here are the methods used for impact, friction, electrostatic discharge, and differential scanning calorimetry analysis during the IDCA program. These methods changed throughout the Proficiency Test and the reasons for these changes are documented in this report. The most significant modifications in standard testing methods are: 1) including one specified sandpaper in impact testing among all the participants, 2) diversifying liquid test methods for selected participants, and 3) including sealed sample holders for thermal testing by at least one participant. This effort, funded by the Department of Homeland Security (DHS), is putting the issues of safe handling of these materials in perspective with standard military explosives. The study is adding SSST testing results for a broad suite of different HMEs to the literature. Ultimately the study will suggest new guidelines and methods and possibly establish the SSST testing accuracies needed to develop safe handling practices for HMEs. Each participating testing laboratory uses identical test materials and preparation methods wherever possible. The testing performers involved are Lawrence Livermore National Laboratory (LLNL), Los Alamos National Laboratory (LANL), Indian Head Division, Naval Surface Warfare Center, (NSWC IHD), Sandia National Laboratories (SNL), and Air Force Research Laboratory (AFRL/RXQL). These tests are conducted as a proficiency study in order to establish some consistency in test protocols, procedures, and experiments and to compare results when these testing variables cannot be made consistent.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2011

TREATMENT TANK OFF-GAS TESTING FOR THE ENHANCED CHEMICAL CLEANING PROCESS

The purpose of this activity was to provide a bounding estimate of the volume of hydrogen gas generated during Enhanced Chemical Cleaning (ECC) of residual sludge remaining in a Type I or Type II treatment tank as well as to provide results independent of the sludge volume in the waste tank to be cleaned. Previous testing to support Chemical Cleaning was based on a 20:1 oxalic acid to sludge ratio. Hydrogen gas evolution is the primary safety concern. Sealed vessel coupon tests were performed to estimate the hydrogen generation rate due to corrosion of carbon steel by 2.5 wt.% oxalic acid. These tests determined the maximum instantaneous hydrogen generation rate, the rate at which the generation rate decays, and the total hydrogen generated. These values were quantified based on a small scale methodology similar to the one described in WSRC-STI-2007-00209, Rev. 0. The measured rates support identified Safety Class functions. The tests were performed with ASTM A285 Grade C carbon steel coupons. Bounding conditions were determined for the solution environment. The oxalic acid concentration was 2.5 wt.% and the test temperature was 75 C. The test solution was agitated and contained no sludge simulant. Duplicate tests were performed and showed excellent reproducibility for the hydrogen generation rate and total hydrogen generated. The results showed that the hydrogen generation rate was initially high, but decayed rapidly within a couple of days. A statistical model was developed to predict the instantaneous hydrogen generation rate as a function of exposure time by combining both sets of data. An upper bound on the maximum hydrogen generation rate was determined from the upper 95% confidence limit. The upper bound confidence limit for the hydrogen generation rate is represented by the following equation. ln (G{sub v}) = -8.22-0.0584 t + 0.0002 t{sup 2}. This equation should be utilized to estimate the instantaneous hydrogen generation rate per unit surface area, G{sub v}, at a given time, t. The units for G{sub v} and t are ft{sup 3}/ft{sup 2}/min and hours, respectively. The total volume of hydrogen gas generated during the test was calculated from the model equation. An upper bound on the total gas generated was determined from the upper 95% confidence limit. The upper bound limit on the total hydrogen generated during the 163 hour test was 0.332 ft{sup 3}/ft{sup 2}. The maximum instantaneous hydrogen generation rate for this scenario is greater than that previously measured in the 8 wt.% oxalic acid tests due to both the absence of sludge in the test (i.e., greater than 20:1 ratio of acid to sludge) and the use of polished coupons (vs. mill scale coupons). However, due to passivation of the carbon steel surface, the corrosion rate decays by an order of magnitude within the first three days of exposure such that the instantaneous hydrogen generation rates are less than that previously measure in the 8 wt.% oxalic acid tests. While the results of these tests are bounding, the conditions used in this study may not be representative of the ECC flowsheet, and the applicability of these results to the flowsheet should be evaluated for the following reasons: (1) The absence of sludge results in higher instantaneous hydrogen generation rates than when the sludge is present; and (2) Polished coupons do not represent the condition of the carbon steel interior of the tank, which are covered with mill scale. Based on lower instantaneous corrosion rates measured on mill scale coupons exposed to oxalic acid, lower instantaneous hydrogen generation rates are expected for the tank interior than measured on the polished coupons. Corrosion rates were determined from the coupon tests and also calculated from the measured hydrogen generation rates. Excellent agreement was achieved between the time averaged corrosion rate calculated from the hydrogen generation rates and the corrosion rates determined from the coupon tests. The corrosion rates were on the order of 18 to 28 mpy. Good agreement was also observed between the maximum instantaneous corrosion rate as calculated from the hydrogen generation rate and the corrosion rate determined by previous electrochemical tests.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Aquifer Hydraulic Testing and Characterization Plan for the Ringold Formation Unit A in the Hanford 200-ZP-1 Groundwater Operable Unit and Vicinity

This document presents a plan for testing and characterizing the hydraulic properties of the Ringold Formation, member of Wooded Island – unit A (Rwia) in the 200-ZP groundwater operable unit. The testing approach includes multiple field methods and associated analyses designed to investigate and understand aquifer hydraulic properties over a range of scales. Testing was designed to achieve specific testing objectives identified previously in the 200 ZP-1 Groundwater Operable Unit Ringold Formation Unit A Characterization Sampling and Analysis Plan (Ringold A SAP). The test plan provides necessary technical and operational detail for writing subsequent field test instruction documents specific to each testing location. Hydraulic characterization activities will proceed in a phased manner focusing on areas identified to have knowledge gaps and also critical for remedy modifications and/or selection. These activities are designed to minimize impact to pump-and-treat (P&T) operations and to use existing P&T injection and extraction wells as stress wells, and include use of the new Rwia monitoring wells installed for Ringold A SAP activities. ZP-1 hydraulic testing will include slug testing in new Rwia wells, shutdown-recovery tests in multiple Rwia and composite Ringold Formation member of Wooded Island – unit E (Rwie)-Rwia aquifer test locations, installation of new Automated Water Level Network stations in Rwia monitoring wells, characterization of P&T and barometric responses, identifying the vertical distribution of hydraulic conductivity in the Rwia and Rwie units using electromagnetic borehole flowmeter tests, and single-well tracer testing in select Rwia monitoring wells. Slug testing to be conducted during drilling is described under the Ringold A SAP. The remaining testing activities are to be conducted after well drilling and completion and are described in this test plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Generic characterization of electrical test benches for AC- and HVDC-connected wind power plants

The electrical test and assessment of wind turbines go hand in hand with standards and network connection requirements. In this paper, the generic structure of advanced electrical test benches, including grid emulator or controllable grid interface, wind torque emulator, and device under test, is proposed to harmonize state-of-the-art test sites. On the other hand, modern wind turbines are under development towards new features, concerning grid-forming, black-start, and frequency support capabilities as well as harmonic stability and control interaction considerations, to secure the robustness and stability of renewable-energy-based power systems. Therefore, it is necessary to develop new and revised test standards and methodologies to address the new features of wind turbines. This paper proposes a generic test structure within two main groups, including open-loop and closed-loop tests. The open-loop tests include the IEC 61400-21-1 standard tests as well as the additional proposed test options for the new capabilities of wind turbines, which replicate grid connection compliance tests using open-loop references for the grid emulator. In addition, the closed-loop tests evaluate the device under test as part of a virtual wind power plant and perform real-time simulations considering the grid dynamics. The closed-loop tests concern grid connection topologies consisting of AC and HVDC, as well as different electrical characteristics, including impedance, short-circuit ratio, inertia, and background harmonics. The proposed tests can be implemented using available advanced test benches by adjusting their control systems. The characteristics of a real power system can be emulated by a grid emulator coupled with real-time digital simulator systems through a high-bandwidth power-hardware-in-the-loop interface.

17 WIND ENERGY↗

NASA NTRS2005

Force Limited Vibration Testing

This slide presentation reviews the concept and applications of Force Limited Vibration Testing. The goal of vibration testing of aerospace hardware is to identify problems that would result in flight failures. The commonly used aerospace vibration tests uses artificially high shaker forces and responses at the resonance frequencies of the test item. It has become common to limit the acceleration responses in the test to those predicted for the flight. This requires an analysis of the acceleration response, and requires placing accelerometers on the test item. With the advent of piezoelectric gages it has become possible to improve vibration testing. The basic equations have are reviewed. Force limits are analogous and complementary to the acceleration specifications used in conventional vibration testing. Just as the acceleration specification is the frequency spectrum envelope of the in-flight acceleration at the interface between the test item and flight mounting structure, the force limit is the envelope of the in-flight force at the interface . In force limited vibration tests, both the acceleration and force specifications are needed, and the force specification is generally based on and proportional to the acceleration specification. Therefore, force limiting does not compensate for errors in the development of the acceleration specification, e.g., too much conservatism or the lack thereof. These errors will carry over into the force specification. Since in-flight vibratory force data are scarce, force limits are often derived from coupled system analyses and impedance information obtained from measurements or finite element models (FEM). Fortunately, data on the interface forces between systems and components are now available from system acoustic and vibration tests of development test models and from a few flight experiments. Semi-empirical methods of predicting force limits are currently being developed on the basis of the limited flight and system test data. A simple two degree of freedom system is shown and the governing equations for basic force limiting results for this system are reviewed. The design and results of the shuttle vibration forces (SVF) experiments are reviewed. The Advanced Composition Explorer (ACE) also was used to validate force limiting. Test instrumentation and supporting equipment are reviewed including piezo-electric force transducers, signal processing and conditioning systems, test fixtures, and vibration controller systems. Several examples of force limited vibration testing are presented with some results.

random vibration testing↗

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