Photoheliograph Functional Verification Unit Test and Operations Plan, November 1967 - June 1968
Test and operations plan for functional verification unit of photoheliograph to be used with Apollo telescope mount
Maclay, J. E.↗
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A Collaborative Web-Based Approach to Planning Research, Integration, and Testing Using a Wiki
The National Aeronautics and Space Administration Integrated Vehicle Health Management program touches on many different research areas while striving to enable the automated detection, diagnosis, prognosis, and mitigation of adverse events at the aircraft and system level. At the system level, the research focus is on the evaluation of multidisciplinary integrated methods, tools, and technologies for achieving the program goal. The participating program members form a diverse group of government, industry, and academic researchers. The program team developed the Research and Test Integration Plan in order to track significant test and evaluation activities, which are important for understanding, demonstrating, and communicating the overall project state and project direction. The Plan is a living document, which allows the project team the flexibility to construct conceptual test scenarios and to track project resources. The Plan also incorporates several desirable feature requirements for Plan users and maintainers. A wiki has proven to be the most efficient and effective means of implementing the feature requirements for the Plan. The wiki has proven very valuable as a research project management tool, and there are plans to expand its scope.
Delaney, Michael M.↗
Characterization of Embedded Sensors in Stainless Steel Test Articles and Design/Planning for MAGNET Testing
The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Fifteen-foot diameter modular space station Kennedy Space Center launch site support definition (space station program Phase B extension definition)
This document defines the facilities, equipment, and operational plans required to support the MSS Program at KSC. Included is an analysis of KSC operations, a definition of flow plans, facility utilization and modifications, test plans and concepts, activation, and tradeoff studies. Existing GSE and facilities that have a potential utilization are identified, and new items are defined where possible. The study concludes that the existing facilities are suitable for use in the space station program without major modification from the Saturn-Apollo configuration.
Bjorn, L. C.↗
Safety assessment for EPS electron-proton spectrometer
A safety analysis was conducted to identify the efforts required to assure relatively hazard free operation of the EPS and to meet the safety requirements of the program. Safety engineering criteria, principles, and techniques in applicable disciplines are stressed in the performance of the system and subsystem studies; in test planning; in the design, development, test, evaluation, and checkout of the equipment; and the operating procedures for the EPS program.
Gleeson, P.↗
Test of acoustic tone source and propulsion performance of C8A Buffalo suppressor nozzle
Results are presented for a static acoustic and propulsion performance ground test conducted at the Boeing hot nozzle facility on the C8A Buffalo noise suppressor nozzle. Various methods to remove a nozzle-associated 2000-Hz tone are evaluated. Results of testing this rectangular-array lobed nozzle for propulsion performance and acoustic directivity are reported. Recommendations for future nozzle modifications and further testing are included. Appendix A contains the test plan. Appendix B presents the test log. Appendix C contains plots of the one-third octave sound pressure levels recorded during the test. Appendix D describes the acoustic data recording and reduction systems. The performance data is tabulated in Appendix E.
Marrs, C. C.↗
Space Shuttle stability and control flight test techniques
A unique approach for obtaining vehicle aerodynamic characteristics during entry has been developed for the Space Shuttle. This is due to the high cost of Shuttle testing, the need to open constraints for operational flights, and the fact that all flight regimes are flown starting with the first flight. Because of uncertainties associated with predicted aerodynamic coefficients, nine flight conditions have been identified at which control problems could occur. A detailed test plan has been developed for testing at these conditions and is presented. Due to limited testing, precise computer initiated maneuvers are implemented. These maneuvers are designed to optimize the vehicle motion for determining aerodynamic coefficients. Special sensors and atmospheric measurements are required to provide stability and control flight data during an entire entry. The techniques employed in data reduction are proven programs developed and used at NASA/DFRC.
Cooke, D. R.↗
Heat pipes for wing leading edges of hypersonic vehicles
Wing leading edge heat pipes were conceptually designed for three types of vehicle: an entry research vehicle, aero-space plane, and advanced shuttle. A full scale, internally instrumented sodium/Hastelloy X heat pipe was successfully designed and fabricated for the advanced shuttle application. The 69.4 inch long heat pipe reduces peak leading edge temperatures from 3500 F to 1800 F. It is internally instrumented with thermocouples and pressure transducers to measure sodium vapor qualities. Large thermal gradients and consequently large thermal stresses, which have the potential of limiting heat pipe life, were predicted to occur during startup. A test stand and test plan were developed for subsequent testing of this heat pipe. Heat pipe manufacturing technology was advanced during this program, including the development of an innovative technique for wick installation.
Boman, B. L.↗
Rain-fade simulation and power augmentation for satellite communication systems
The design and implementation of an automated rain-fade simulation and power augmentation system is presented. The system experimentally simulates and measures the effects of radiofrequency power fade on a 20 GHz communication link using a multimode travelling wave tube amplifier for loss compensation. Precision, computer-controlled attenuators are used in the fade simulation. Test plans for analog and digital testing are discussed.
Shalkhauser, Kurt A.↗
Design of lightning protection for a full-authority digital engine control
The steps and procedures are described which are necessary to achieve a successful lightning-protection design for a state-of-the-art Full-Authority Digital Engine Control (FADEC) system. The engine and control systems used as examples are fictional, but the design and verification methods are real. Topics discussed include: applicable airworthiness regulation, selection of equipment transient design and control levels for the engine/airframe and intra-engine segments of the system, the use of cable shields, terminal-protection devices and filter circuits in hardware protection design, and software approaches to minimize upset potential. Shield terminations, grounding, and bonding are also discussed, as are the important elements of certification and test plans, and the role of tests and analyses. Also included are examples of multiple-stroke and multiple-burst testing. A review of design pitfalls and challenges, and status of applicable test standards such as RTCA DO-160, Section 22, are presented.
Dargi, M.↗
From an automated flight-test management system to a flight-test engineer's workstation
The capabilities and evolution is described of a flight engineer's workstation (called TEST-PLAN) from an automated flight test management system. The concept and capabilities of the automated flight test management systems are explored and discussed to illustrate the value of advanced system prototyping and evolutionary software development.
Duke, E. L.↗
Early lunar rover mission studies
Results of lunar mission studies aimed at developing mission goals and high level requirements are reported. A mission concept to meet the mission requirements was developed and the design of mission hardware was to follow. Mission concepts not only included operations analysis and plans but also fabrication and test planning, quality control measures, and project organization. The design of mission concepts and hardware identified issues that are not easily resolved. Although none of the issues identified appear to be unresolvable, many will be difficult to resolve within Space Exploration Initiative constraints. These issues discussed which appear to have the potential for negative project impact are rover mobility, power, imaging, telemanagment, and remote control.
Gillespie, Vernon P.↗
The Trash Compaction Processing Systems (TCPS) Ground Unit Control Sample Testing
The Trash Compaction Processing System (TCPS) is being developed by NASA and Sierra Space to process crew trash for long-duration missions. The system compacts and thermally processes mixed spacecraft waste to reduce volume and stabilize the material while managing gas and liquid effluents. A Ground Unit (GU) located at Sierra Space in Madison, Wisconsin was used to run a series of tests using standardized control samples representing different trash conditions, including nominal, high liquid, high cloth, benign, and foam. Gas grab samples were collected during processing and analyzed to identify the compounds present in the effluent stream and compare the concentrations to the NASA spacecraft maximum allowable concentrations (SMACs). Additional testing included odor testing at White Sands Test Facility, aerosol measurements, microbiology, and tile characterization. Overall, the compounds detected in the gas samples were well below the SMAC limits for all trash models tested. The results from this testing are being used to help guide the verification approach and test planning for the TCPS Flight Unit that is planned for on-orbit testing on the International Space Station.
Control Samples↗
Progress on Advancing the Robotic Air-slot Volumetric Inspection System (RAVIS) for Hanford Under-tank Inspection - 20519
The 27 in-service double-shell tank (DST) systems at Hanford provide interim storage for nearly 56 million gallons of nuclear and hazardous chemical legacy waste. The safe and reliable storage of the waste is critical to the site's extended cleanup mission. While in service, the leak integrity of the DSTs must be demonstrated to satisfy the Washington Administrative Code, inform decisions on tank management, and gauge fitness for continued service beyond originally intended design lives. The carbon steel plates and welds that comprise DST primary tank sidewalls and lower knuckles are routinely 'sampled' for volumetric non-destructive testing using ultrasonic inspection technology to determine whether corrosion pitting, cracking, or general corrosion are occurring that could compromise tank leak integrity. However, the carbon steel plates and welds that comprise the bottoms of primary tanks have not been thoroughly inspected since the DSTs were constructed (i.e., since 1968-1986) due to limited physical access to the exterior tank bottoms. The Robotic Air-slot Volumetric Inspection System, or 'RAVIS,' is being engineered to overcome the challenge of tank bottom in-service inspection. The system will be deployed under primary tanks within the small cooling channels/air-slots in the refractory pads upon which the tanks rest and will use ultrasonic guided wave inspection technology to volumetrically inspect physically inaccessible regions that make up ∼90% of a tank bottom, as well as regions that are physically accessible from the air-slots but comprise only ∼10% of a tank bottom. This paper describes the air-slot sensor and robotic deployment system and focuses on the testing approach and methods that are being applied to support (1) design feedback and performance acceptance (requirement verification) and (2) performance repeatability/reliability assessments (qualification) to ensure the RAVIS is prepared for successful inservice inspections of primary tank bottoms. Test progress made against the test plan, the results of 2019 testing, and the future outlook are included. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Mercury Speciation During Vitrification of LAW
n this work, laboratory and engineering-scale tests were conducted that mimic the reactive environment of the Hanford Tank Waste Treatment and Immobilization Plant (WTP) low activity waste (LAW) melter and off-gas system in order to assess the speciation of mercury at select points in the processing system. The experimental protocols, test equipment, feed materials used, and rationale for testing are detailed in the Test Plan for this work. Particular attention was paid to the amount and speciation of mercury in submerged bed scrubber (SBS) solutions, which are intended to be recycled back to the melter feed at the WTP. Results are presented from detailed mercury analysis of these solutions using Environmental Protection Agency (EPA) Method 1630 and modifications to this method for dimethyl mercury and methyl mercury as well as EPA Method 1631 and modifications to this method for total, dissolved, elemental, suspended, and ionic mercury. Testing was conducted in two separate sets of experiments: (1) One set of tests (crucible-scale furnace tests) that involved heating small batches of mercury-spiked melter feed in crucibles to determine the amount of mercury retained in the glass and the species of mercury in the exhaust gases; (2) A second set of tests (DM10 melter tests) was planned that involved creating LAW melter plenum gas compositions using the DM10 melter system, injecting mercury into the off-gas stream, and passing that stream though a reactor that simulates various plenum gas conditions. Operational issues led to the need to use one of the VSL DM100 melters in place of the planned DM10 melter for these tests. The speciation of mercury after exposure to those conditions was monitored. In both sets of tests, the exhaust gases were run through a scrubber that was intended to mimic the LAW SBS in order to determine how much of the mercury exiting the melter would be retained in the primary off-gas system fluids and in what form. After passing through the SBS, the exhaust stream was analyzed to determine particulate, ionic, elemental, and total mercury passing downstream of the SBS. In tests employing gases derived from the DM100 melter that were spiked with elemental mercury, the processing system provided gas temperatures and residence times that are representative of the WTP LAW vitrification system in order to assess the effect of those conditions on mercury speciation. The Decontamination Factor (DF) across the system in the tests with mercury-spiked DM100 melter exhaust was determined using the analytical data from EPA Method 30B (Fluegas Adsorption Mercury Speciation (FAMS TM )) exhaust samples and the amount of mercury detected in the SBS solutions. Mercury species used in melter feed crucible scale tests were divalent (chloride and iodide), monovalent (chloride and fluoride), and elemental mercury. Individual tests included only a single form of mercury in the feed. The results for total mercury mass balances in the crucible tests are also presented.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Guide for Oxygen Hazards Analyses on Components and Systems
Because most materials, including metals, will burn in an oxygen-enriched environment, hazards are always present when using oxygen. Most materials will ignite at lower temperatures in an oxygen-enriched environment than in air, and once ignited, combustion rates are greater in the oxygen-enriched environment. Many metals burn violently in an oxygen-enriched environment when ignited. Lubricants, tapes, gaskets, fuels, and solvents can increase the possibility of ignition in oxygen systems. However, these hazards do not preclude the use of oxygen. Oxygen may be safely used if all the materials in a system are not flammable in the end-use environment or if ignition sources are identified and controlled. These ignition and combustion hazards necessitate a proper oxygen hazards analysis before introducing a material or component into oxygen service. The objective of this test plan is to describe the White Sands Test Facility oxygen hazards analysis to be performed on components and systems before oxygen is introduced and is recommended before implementing the oxygen component qualification procedure. The plan describes the NASA Johnson Space Center White Sands Test Facility method consistent with the ASTM documents for analyzing the hazards of components and systems exposed to an oxygen-enriched environment. The oxygen hazards analysis is a useful tool for oxygen-system designers, system engineers, and facility managers. Problem areas can be pinpointed before oxygen is introduced into the system, preventing damage to hardware and possible injury or loss of life.
Stoltzfus, Joel M.↗
Underground Test Area Activity Waste Management Plan; and Attachment 1 Fluid Management Plan for the Underground Test Area Activity
The U.S. Department of Energy, National Nuclear Security Administration Nevada Field Office initiated the Underground Test Area Activity to characterize the risk posed to human health and the environment as a result of underground nuclear testing activities at the Nevada National Security Site. The UGTA Activity is now administered by the DOE Environmental Management Nevada Program. This document is a revision to NNSA/NSO (2009). The new document and revision number reflect EM Nevada Program as the current UGTA Activity administrator.
54 ENVIRONMENTAL SCIENCES↗
Development of Monte Carlo Capability for Orion Parachute Simulations
Parachute test programs employ Monte Carlo simulation techniques to plan testing and make critical decisions related to parachute loads, rate-of-descent, or other parameters. This paper describes the development and use of a MATLAB-based Monte Carlo tool for three parachute drop test simulations currently used by NASA. The Decelerator System Simulation (DSS) is a legacy 6 Degree-of-Freedom (DOF) simulation used to predict parachute loads and descent trajectories. The Decelerator System Simulation Application (DSSA) is a 6-DOF simulation that is well suited for modeling aircraft extraction and descent of pallet-like test vehicles. The Drop Test Vehicle Simulation (DTVSim) is a 2-DOF trajectory simulation that is convenient for quick turn-around analysis tasks. These three tools have significantly different software architectures and do not share common input files or output data structures. Separate Monte Carlo tools were initially developed for each simulation. A recently-developed simulation output structure enables the use of the more sophisticated DSSA Monte Carlo tool with any of the core-simulations. The task of configuring the inputs for the nominal simulation is left to the existing tools. Once the nominal simulation is configured, the Monte Carlo tool perturbs the input set according to dispersion rules created by the analyst. These rules define the statistical distribution and parameters to be applied to each simulation input. Individual dispersed parameters are combined to create a dispersed set of simulation inputs. The Monte Carlo tool repeatedly executes the core-simulation with the dispersed inputs and stores the results for analysis. The analyst may define conditions on one or more output parameters at which to collect data slices. The tool provides a versatile interface for reviewing output of large Monte Carlo data sets while preserving the capability for detailed examination of individual dispersed trajectories. The Monte Carlo tool described in this paper has proven useful in planning several Crew Exploration Vehicle parachute tests.
Moore, James W.↗