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At least 37 records · Page 2

Success Path Method: Conformance with Safety Management Systems

All industrial facilities deal with safety hazards such as equipment failures, chemical and toxic releases, and fires and explosions just to name a few. A disciplined framework for managing the integrity of operating systems and processes that handle hazardous substances by applying good design principles, engineering, and operating practices is called process safety. The goal of such framewoks is to prevent the release of energy or material that could cause harm to people or damage to equipment and/or environment. Process safety covers all aspects of facility operation also including design, maintenance, and human and organizational factors that could possibly have effect on process safety. As it will be seen from the discussion below, process safety is just one of the pieces of the much bigger matter, a safety culture. Many industries have long recognized the importance of safety culture in their day-to-day operation. Although the definition of safety culture can slightly differ from organization to organization, in general, a safety culture is how things are done to demonstrate a commitment to safety by everyone involved. An organization acquires safety culture over time as the product of individual and group values, actions, and behaviors toward overall safety. It is important to note that safety culture should not be viewed as some static state that an organization wants to reach. It is more like a constantly evolving level of “how things are done when nobody is watching.” Safety culture is an inherent characteristic of an organization, it is always present, but the level can range on a continuum from undesirable to desirable or more commonly used, from negative to positive. An example for an undesirable, negative safety culture would be a company in which accidents resulting in harm (physical and/or emotional) of its employees, equipment or surrounding environment and community occur frequently. At the other end of the spectrum would be a company in which such accidents are rare or do not occur at all (desired or positive safety culture). Every company/industry exists somewhere within this spectrum.

42 ENGINEERING

NLR CSP Optical Facilities: Illuminating the Path Forward Through Innovation and Impact: Agreement 38490

This initiative is a multi-faceted project at the National Laboratory of the Rockies (NLR) aimed at strengthening its Concentrating Solar Power (CSP) Optical Facilities to advance the development of low-cost, high-performance materials for solar and other applications. The project's strategy is built on three pillars: strategic stakeholder engagement, diligent facility maintenance and utilization, and the development of new research capabilities. The overarching goal is to ensure the facilities remain state-of-the-art resources for industry and academia, thereby accelerating the conversion of concentrated sunlight into energy. A key driver of the project is an international Advisory Board, which provides critical guidance on research priorities and industry needs, leading to new collaborations and secured funding. This external engagement, combined with proactive outreach to industry partners, ensures the lab's work remains aligned with real-world challenges, including materials durability and performance certification. Significant efforts in facility maintenance have addressed challenges with aging infrastructure. Notable achievements include the complete refurbishment of the hail-damaged Ultra-Accelerated Weathering System (UAWS) and the successful replacement of a failing 15-year-old Lambda 1050 spectrophotometer with a new-generation model, substantially upgrading material characterization capabilities. These maintenance activities were complemented by achieving a prestigious ISO 9001:2015 certification for the Advanced Optical Materials Labs, formally recognizing the quality and reliability of NLR's measurement capabilities. Despite these successes, challenges remain, including high demand for the High Flux Solar Furnace (HFSF) and intermittent failures of other key instruments. The project has delivered major advancements in research techniques and capabilities. At the Flatirons campus, a new indoor laboratory, was established to house advanced deflectometry and photogrammetry systems for heliostat characterization. For on-sun testing, a novel, actively cooled turning mirror was developed for the HFSF, enabling more realistic testing of particle receivers and components. A collaboration with Virginia Tech successfully demonstrated the high-temperature durability of a new solar absorber coating through extensive cyclic testing. Concurrently, new modeling took place to better predict material degradation on rough, fractal surfaces. In summary, this project has systematically enhanced NLR's CSP Optical Facilities through strategic upgrades, rigorous maintenance, and stakeholder-guided research. By overcoming equipment failures, budgetary constraints, and logistical hurdles, the project has reinforced NLR's role as a central hub for CSP innovation and materials testing. Future work will focus on securing diverse funding, expanding collaborations, and continuing to provide the critical infrastructure needed to accelerate the development and deployment of next-generation technologies.

14 SOLAR ENERGY

Plant Growth During the Greenhouse II Experiment on the MIR Orbital Station

We carried out three experiments with Super Dwarf wheat in the Bulgarian/Russian growth chamber Svet (0.1 sq m growing area) on the Space Station Mir. This paper mostly describes the first of these NASA-supported trials, began on Aug. 13, 1995. Plants were sampled five times and harvested on Nov. 9 after 90 days. Equipment failures led to low irradiance (three, then four of six lamp sets failed), instances of high temperatures (ca. 37 C), and sometimes excessive-substrate moisture. Although plants grew for the 90 days, no wheat heads were produced. Considering the low light levels, plants were surprisingly green, but of course biomass production was low. Plants were highly disoriented (low light, mirror walls?). Fixed and dried samples and the root module were returned on the US Shuttle Atlantis on Nov. 20, 1995. Samples of the substrate, a nutrient-charged zeolite called Balkanine, were taken from the root module, carefully examined for roots, weighed, dried, and reweighed. The Svet control unit and the light bank were shipped to Moscow. An experiment validation test (EVT) of plant growth and experiment procedures, carried out in Moscow, was highly successful. Equipment built in Utah to measure CO2, H2O vapor, irradiance, air and leaf (IR) temperature, O2, pressure, and substrate moisture worked well in the EVT and in space. After this manuscript was first prepared, plants were grown in Mir with a new light bank and controller for 123 days in late 1996 and 39 days in 1996/1997. Plants grew exceptionally well with higher biomass production than in any previous space experiment, but the ca. 280 wheat heads that were produced in 1996 contained no seeds. Ethylene in the cabin atmosphere was responsible.

Salisbury, F. B.

Electrodynamic Dust Shield (EDS) Preparation for MISSE-11 Launch

The dusty surfaces of the Moon, Mars, and various asteroids present a significant challenge to NASA’s manned and unmanned space exploration efforts. The fine, electrostatically charged dust is difficult to remove and has resulted in vision obscuration, false instrument readings, contamination, elevated temperatures, performance reduction, and equipment failure. To alleviate these problems, NASA KSC’s Electrostatics and Surface Physics Laboratory (ESPL) is developing active dust mitigation systems for solar system exploration and in situ resource utilization (ISRU). Part of KSC’s Swamp Works system, the lab emphasizes fast-paced, hands-on, cost-effective, and collaborative innovation. The Electrodynamic Dust Shield (EDS) is an ESPL technology being developed to prevent dust accumulation on space components. It consists of a dielectric substrate embedded with parallel electrodes which, when applied with high voltage out-of-phase waveforms, produce a traveling electric field wave that scatters dust particles from its surface via dielectrophoretic and electrostatic forces. The EDS is currently fully functional and has been tested for scalability and endurance in reduced gravity/pressure flight. Next, it will be part of the May 2019 Materials International Space Station Experiment-11 (MISSE-11) payload, which will test small shield samples for performance durability with exposure to the harsh space environment. The summer objective was to test EDS functionality before active and passive dust shield samples launch on MISSE-11, in order to screen for good flight/control samples as well as to compare pre-flight and post-flight clearing efficiencies. I imaged glass and Kapton shields of 2-phase and 3-phase electrode configurations with the Keyence VHX-5000 digital microscope to check for damage before and after all testing for a qualitative pre-flight baseline; helped with vacuum testing of high-voltage shield breakdown; assembled shields and wires using Electrobond 004 silver epoxy; and helped with vacuum and cryogenic dust clearance testing of assembled EDS systems. I learned CAD (computer-aided design) and 3D printing skills to create parts for a shaker table/motor assembly, which will allow for repeatable experiments by evening out EDS dust distribution in a consistent manner prior to dust scattering testing. I will also be improving the interfacing with Alpha Space’s prototype Data Communications Unit (DCU), a payload component to control power to the EDS and store data, by mapping the DCU structure upon power-up and writing shell scripts to improve various processes. Finally, I also CADed and 3D-printed plastic supports for three different geometries of the Electrostatic Precipitator (ESP), a project that aims to use high voltage electrodes to charge and filter out dust from the Martian atmosphere drawn for ISRU devices. This work on dust mitigation technologies will help to support future robotic and human space exploration missions, including NASA’s Journey to Mars; the EDS has especially significant applications to spacecraft solar panels, thermal radiators, viewports, and astronaut visors. This opportunity has also allowed me to become more familiar with various lab equipment and hardware testing, develop key modeling skills in SolidWorks, explore past and present components critical to America’s space program, work with inspiring peers and mentors, and ascertain my dream of working permanently for NASA.

space

Contaminant Investigation and Pre‐Processing Opportunities for Textile‐To‐Textile Recycling

Millions of metric tons of textiles are landfilled or incinerated each year in the United States, with less than 1% of textiles recycled into new clothing or fabrics. To counter this trend, a growing number of companies and researchers are exploring how a circular economy can be applied to support textile‐to‐textile recycling. A significant barrier they face comes down to quickly and efficiently extracting pure feedstock material from post‐consumer garments that feature a mix of natural and synthetic fibers. Textile recyclers prefer pure feedstocks, as working with mixed sources typically means lower throughput, higher risk of equipment failure, and diminished business margins. To facilitate a circular economy for textiles, methods, and technologies are needed that can efficiently separate out materials and contaminants from end‐of‐life textiles to increase the flow of pure feedstocks to recyclers. This paper summarizes findings from interviews with a cross section of textile recyclers and from a review of literature to define basic feedstock requirements. In addition to our qualitative research, we deconstruct a bale of post‐consumer textiles and analyze them using computer‐vision imaging, Fourier transform infrared spectroscopy (FTIR), and machine learning. The resulting data are used to set system‐level design inputs for an automated contaminant removal system to process post‐consumer clothing into appropriate feedstocks for recycling. To set the system's levels for automated real‐time near‐infrared analysis, we identify the minimum percentage of primary material that any single garment in a load of used clothing must contain for the average of the full output stream to meet the target purity levels of recyclers. Here, the envisioned automated system can also address undesirable trace materials that might contaminate the processed stream by using imaging cameras coupled with artificial intelligence to identify sections of clothing for de‐trimming. Proof‐of‐concept machine learning algorithms are evaluated to locate and identify trims or garment areas with hidden contaminant materials. Integrating these methods into automated textile cutting systems can provide a cost‐effective means for increasing feedstock purity from used clothing, which can advance circularity for textiles by helping recyclers to reach production volumes and quality targets that were not possible solely with manual dismantling operations.

Parsons, Ryan [Rochester Institute of Technology,

Paper or Plastic? Multiscale Material Handling Properties of Two Model Municipal Solid Waste Streams

Purpose: Municipal Solid Waste (MSW) is a potentially valuable sustainable feedstock for fuel and chemical production due to its carbon-rich content and low cost. This study aims to assess the material handling properties of paperand plastic-rich MSW feedstocks to mitigate equipment failure and processing downtime. Methods: The material handling properties of crumbled MSW feedstocks were measured using apowder rheometer with mass flow hopper calculations to assess handling performance. Inverse gas chromatography was use to measure the surface energy differences between feedstocks. Electron microscopy and Raman spectroscopy was used to evaluate microscale features that may contribute to material handling differences. Results: Plastic and paper rich feedstocks crumbled to a nominal 2 mm particle size were observed to have similar flow and handling characteristics with reasonable hopper outlets. 2 mm plastic rich crumbles, with their higher bulk density, exhibited superior flow performance. By contrast, 4 mm material required significantly larger hopper outlets, indicating poor flowability. Paper rich and 4 mm plastic rich samples displayed broad particle size distributions, which contributed to particle interlocking, jamming, and other flow issues. Electron microscopy revealed that plastic rich samples were significantly smoother, enhancing their flowability compared to the rougher, paper rich materials. Conclusions: This study establishes critical material handling baselines for processing MSW as a viable feedstock for fuel and chemical production. The findings highlight the importance of optimizing particle size and feedstock composition to improve flowability and handling performance.

09 BIOMASS FUELS

Economic Analysis of Condition-Monitoring-Based Predictive Maintenance in Power Plants under Market Elasticity

Condition-monitoring-based predictive maintenance can increase the power plant availability by preventing forced outages. However, the actual on-stream time depends on market elasticity and dynamics, which are affected by cost and penetration of other power generation technologies. This paper develops a systematic approach for the economic analysis of investment in condition monitoring technologies with due consideration of market elasticity. Focus is on corrosion monitoring in coal-fired power plants (CFFPs) since corrosion in high-temperature coal-fired boilers is a leading cause of equipment failure. Investment in sensor networks for measuring corrosion and operating conditions like metal temperature and concentrations of O 2 and SO 2 is investigated. The unscented Kalman filter is used to estimate corrosion in the waterwall section of the boiler under multiple sensor networks. Electricity produced by CFPPs in the future in the U.S. due to changes in availability under market elasticity is studied. Sensitivity of the incremental net present value to factors like the number, type, and cost of sensors is analyzed.

Electrochemistry

Risk-controlled Expansion Planning with Distributed Resources (REPAIR) v1.0

The Risk-controlled Expansion Planning with Distributed Resources (REPAIR) is an innovative tool to support decisions around utility grid planning to prevent and mitigate the impact of outages caused by routine equipment failures (reliability) or by extreme events (resilience), such as storms, earthquakes or wildfires that long term interruption of service. REPAIR is a risk-based optimization and decision-making model allowing informed and transparent "cost vs risk" decisions regarding infrastructural planning of electric utilities. The model considers long-term resilience and reliability planning strategies that rely on traditional infrastructure upgrade (e.g. circuit hardening, reinforcement, new substations, etc.) or new investment alternatives, such as DERs.

Heleno, Miguel [Lawrence Berkeley National Laborat

Woody Feedstock 2022 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for n th -plant and 1 st -plant woody biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for woody biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Conventional feedstock supply systems need to be modified to meet the demands of conversion pathways, specifically to have the ability to adjust the quality of the raw biomass materials. Advanced systems incorporate innovative methods of material handling, preprocessing and supply chain configuration. In advanced designs, variability of the raw biomass can be reduced to produce feedstocks of a uniform format, moving toward biomass commoditization. Against this backdrop, the 2022 Woody SOT for low-ash woody feedstocks utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (wood, bark, needle, and extrinsic ash) to reduce impurities and attempt to maximize the retention of usable fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in forest residues, separate out a majority of the incoming needles (which can be supplied to alternate markets), and maximize the retention of whitewood in the usable fraction. The fractionated forest residues are then mixed with clean-pine chips in a 50-50 blend to prepare the feedstock for the desired conversion pathway. The n th -plant analysis estimated the delivered cost for the feedstock at $\$$69.23/dry ton (2016$\$$) which represents a $\$$6.64/dry ton decrease compared to the cost estimate of the 2021 Woody SOT supply system for low-ash woody feedstocks. The quality requirements in the 2022 Woody SOT were identical to those of the 2021 Woody SOT at = 1.00 wt % ash and = 50.51 wt% carbon. The cost savings derive primarily from reductions in dry matter losses during air classification. The GHG emissions for the n th -plant analysis were estimated at 178.39 kg CO2e/dry ton compared to 178.71 kg CO 2 e/dry ton in the 2021 Woody SOT, a decrease of 0.32 kg CO2e/dry ton. The small change stems from an increase in emissions attributed to preprocessing and slightly larger savings in emissions from transportation. In the 1 st -plant analysis of the 2022 Woody SOT system, the average throughput was estimated to be approximately 2,128 dry tons/day or 96.51% of the name plate capacity. During the simulation the daily throughput ranged from 1,090 dry tons/day to 2,200 dry tons/day, or 49.43% to 99.75% of the daily nameplate capacity. After the year of operation 722,403 tons of processed feedstock were produced in total without regard to quality considerations (99.64% of the annual nameplate capacity). The variability in throughput was primarily caused by equipment failures in the system. Regular failures, downtime caused by routine maintenance per manufacturer guidelines, contributed to a majority 62.50% of failures and 62.60% of downtime. Failures due to wear were the other cause of disruption within the system, impacting the rotary shear and orbital screen and accounting for 37.50% of the failures and 37.40% of the total downtime. Ultimately the system was on stream for 87.84% during the simulation period, which is only 2.16 percentage points below the nth-plant assumption for on-stream time. The production cost of the system averaged $\$$71.66/dry ton. The costs ranged from a minimum of $\$$71.23/dry ton to a maximum of $\$$2,115.30/dry ton. When dry matter losses (disposed low-quality fractions as well as other losses such as in grinders) were considered the costs increased to an average of $\$$75.11/dry ton with a minimum of $\$$74.69/dry ton and a maximum of $\$$2,136.86/dry ton...

09 BIOMASS FUELS

Evaluating Liquid Waste Transfers and their Impacts to the SRS Tank Farms to Support Operations and Closure

BACKGROUND • SRMC mission critical milestones – 34 million liters (9 million gallons) Salt Waste Processing Facility (SWPF) Processing Rate – Accelerated Waste Tank Closures • Results in an increase in Tank Farm transfers • Barriers – Equipment failures, replacements, and adjustments – Weather – Procedure development – Outside facility changes How has the Tank Farm adapted to meet these milestones? By improving the transfer evaluation process

Development of the Table of Initial Isolation and Protective Action Distances for the 2024 Emergency Response Guidebook

The transportation of hazardous materials creates numerous opportunities for the release of toxic substances into the environment, whether caused by traffic accidents, train derailments, equipment failures, or human error. Such releases can pose acute hazards to the general public and to emergency response personnel who are the first to arrive at the scene. To help first responders determine whether a shipment is potentially hazardous and decide what actions should be taken if a toxic spill does occur, the Emergency Response Guidebook (ERG) is published by the U.S. Department of Transportation (DOT), Transport Canada, and the Secretariat of Transport and Communications of Mexico; with contributions from Centro de Informaciòn Quìmica para Emergencias of Argentina. The most recent version is the 2024 edition of the ERG (ERG 2024), titled 2024 Emergency Response Guidebook (ERG2024). The ERG provides essential information about firefighting, spill response, and potential public health effects. For chemicals that are toxic by inhalation (TIH) and chemicals that produce TIH gases upon reaction with water (TIH by water reactivity or TIHWR), the ERG provides initial isolation distances (IIDs) and protective action distances (PADs). The IID defines the radius of the zone around the spill that should be accessed solely by people who are directly involved in emergency response. The PAD is the distance downwind of the source of the release within which persons should be either evacuated or sheltered in place, depending on the severity of the incident and the nature of the population (e.g., density, age, health).

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN

Modular space station phase B extension

The system safety analyses and requirements developed for the modular space station during the phase B extension are reviewed. Residual hazards and unresolved safety issues are summarized. Hazards resulting from equipment failures or malfunctions, operations, or credible accidents are identified and evaluated. Special safety trade studies are presented.

Source record

Assessment of the risk due to release of carbon fiber in civil aircraft accidents, phase 2

The risk associated with the potential use of carbon fiber composite material in commercial jet aircraft is investigated. A simulation model developed to generate risk profiles for several airports is described. The risk profiles show the probability that the cost due to accidents in any year exceeds a given amount. The computer model simulates aircraft accidents with fire, release of fibers, their downwind transport and infiltration of buildings, equipment failures, and resulting ecomomic impact. The individual airport results were combined to yield the national risk profile.

Pocinki, L.

Carbon/graphite fiber risk analysis and assessment study: Assessment of risk to the Lockheed Model L-1011 commercial transport aircraft

The risk associated with the accidental release of carbon/graphite fibers (CF) from fires on commercial transport aircraft incorporating composite materials was assessed. Data are developed to evaluate the potential for CF damage to electrical and electronic equipment, assess the cost risk, and evaluate the hazard to continued operation. The subjects covered include identification of susceptible equipments, determination of infiltration transfer functions, analysis of airport operations, calculation of probabilities of equipment failures, assessment of the cost risk, and evaluation of the hazard to continued operation. The results show the risks associated with CF contamination are negligible through 1993.

Daniledes, J.

The role of man in space

The roles played by astronauts in space missions are discussed using illustrations from the Spacelab and STS experience, and the implications for the proposed space station are considered. Man's ability to perform successfully for relatively long periods in space is demonstrated, and capabilities in manipulation, EVA, equipment repair and compensation for equipment failure, earth observation, astronomy of sun and stars, and laboratory experimentation are characterized and illustrated with photographs. Space station activities planned include repairs (like that of the Solar Maximum Satellite), maintenance (of the Space Telescope), and construction and involve the use of a manned maneuvering unit, a teleoperator maneuvering system, and/or a manned or unmanned OTV.

Lousma, J. R.

Dynamic Considerations for Control of Closed Life Support Systems

Reliability of closed life support systems depend on their ability to continue supplying the crew's needs during perturbations and equipment failures. The dynamic considerations interact with the basic static design through the sizing of storages, the specification of excess capacities in processors, and the choice of system initial state. A very simple system flow model was used to examine the possibilities for system failures even when there is sufficient storage to buffer the immediate effects of the perturbation. Two control schemes are shown which have different dynamic consequences in response to component failures.

Babcock, P. S.

The alloy undercooling experiment on the Columbia STA 61-C space shuttle mission

An Alloy Undercooling experiment was performed in an electromagnetic levitator during the Columbia STS 61-C mission in January 1986. One eutectic nickel-tin alloy specimen was partially processed before an equipment failure terminated the experiment. Examination of the specimen showed evidence of undercooling and some unusual microstructural features.

Harf, Fredric H.