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At least 487 records · Page 27

Validation Testing for Molten Chloride Reactor Experiment Equipment Removal and Disposal Techniques

The Molten Chloride Reactor Experiment (MCRE) will be the first reactor featuring a fast-spectrum molten chloride circulating nuclear fuel system in the world. Planning for equipment removal and disposal (ERD) of MCRE has identified several technology gaps due to the unique environment of this nuclear experiment. Some of the gaps arise from the application of existing disassembly and/or sizing methods to novel material forms or in novel configurations. Others arise from unknown material behavior. This paper summarizes proposed test plans for ERD validation experiments to address these complicated or unknown equipment removal procedures. At the Waste Management Symposia in 2024, the Idaho National Laboratory (INL) MCRE ERD team presented the challenges associated with hosting multiple nuclear experiments in series with only brief transition periods between systems. Such difficulties include higher dose rates, the presence of radioisotopes infrequently encountered in reactor decommissioning and radioactive waste management, lack of intrinsic remote-operations infrastructure in the test bed, space constraints in the test bed, and contamination minimization requirements. To address these challenges, remote or semi-remote technologies are planned to be implemented in a non-hot cell environment with limited space availability. The team also discussed how a systems engineering approach is being used for conceptual development and design of equipment removal systems to address these challenges. For example, to reduce constraints for the removal of more difficult components, non-activated, noncontaminated elements are planned to be taken out first where possible. Still, there are complexities associated with the remaining components. In this work, the operational framework for MCRE ERD was reviewed for technical gaps and open questions, and test plans were drafted to address these areas. The tests plans were written for the following categories: vision systems, pipe cutting, drill/grout/filler, flush salt, and miscellaneous, with the miscellaneous group consisting of tests like techniques for removing bearings and reflector bricks. The test plans explore material, infrastructure, and staffing requirements needed for test execution. The test plans additionally focus on the evaluation of success. Determining the outcome of a test is imperative - as these explorative actions have the potential to rearrange or re-scope planned ERD activities. Success criteria identified thus far include required tool output, required area(s), debris production and mitigation, and repeatability. Test plans are an essential aspect of the systems engineering approach to MCRE ERD. They are used as the beginning steps in defining use cases for the ERD system. Performance of the validation tests is expected to begin in the summer of 2025 and will take approximately 9 to 12 months to complete. Execution of these plans will be expedited by specifying test needs ahead of time, facilitating efficient interactions with any subcontractors tasked with running the requested tests. Evaluating the outcomes of these tests will inform MCRE ERD procedures and timing and will also identify additional technical constraints for the MCRE ERD System. This upfront process optimization effort will help the project save time and resources at the end of the experiment.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Simulation Testing of Embedded Flight Software

Virtual Real Time (VRT) is a computer program for testing embedded flight software by computational simulation in a workstation, in contradistinction to testing it in its target central processing unit (CPU). The disadvantages of testing in the target CPU include the need for an expensive test bed, the necessity for testers and programmers to take turns using the test bed, and the lack of software tools for debugging in a real-time environment. By virtue of its architecture, most of the flight software of the type in question is amenable to development and testing on workstations, for which there is an abundance of commercially available debugging and analysis software tools. Unfortunately, the timing of a workstation differs from that of a target CPU in a test bed. VRT, in conjunction with closed-loop simulation software, provides a capability for executing embedded flight software on a workstation in a close-to-real-time environment. A scale factor is used to convert between execution time in VRT on a workstation and execution on a target CPU. VRT includes high-resolution operating- system timers that enable the synchronization of flight software with simulation software and ground software, all running on different workstations.

Shahabuddin, Mohammad↗

Large Scale Testing of a Foam/Multilayer Insulation Thermal Control System (TCS) for Cryogenic Upper Stages

The development of high energy cryogenic upper stages is essential for the efficient delivery of large payloads to various destinations envisioned in future programs. A key element in such upper stages is cryogenic fluid management (CFM) advanced development/technology. Due to the cost of and limited opportunities for orbital experiments, ground testing must be employed to the fullest extent possible. Therefore, a system level test bed termed the Multipurpose Hydrogen Test Bed (MHTB), which is representative in size and shape (3 meter diameter by 3 meter long with a volume of 18 cubic meters) of a fully integrated space transportation vehicle liquid hydrogen propellant tank has been established. To date, upper stage studies have often baselined the foam/multilayer insulation (FMLI) combination concept; however, hardware experience with the concept is minimal and was therefore selected for the MHTB. The foam element (isofoam SS-1 171 with an average thickness of 3.5 centimeters) is designed to protect against ground hold/ascent flight environments, and allows for the use of a dry nitrogen purge as opposed to the more complex/heavy helium purge subsystem normally required with MLI in cryogenic applications. The MLI (45 layers of Double Aluminized Mylar with Dacron spacers) provides protection in the vacuum environment of space and is designed for an on-orbit storage period of 45 days. Several unique features were incorporated in the MLI concept and included: variable density MLI (reduces weight and radiation losses by changing the layer density), larger but fewer DAM perforations for venting during ascent to orbit (reduces radiation losses), and roll wrap installation of the MLI with a commercially established process to lower assembly man-hours and reduce seam heat leak. Thermal performance testing of the MHTB TCS was conducted during three test series conducted between September 1995 and May 1996. Results for the ground hold portion of the tests were as expected producing an average heat leak of 63 WattS/M2 at an average foam surface temperature of 170 K. The results of the simulated orbit hold test interval produced heat leaks ranging from 0.085 to 0.22 Watts/squareM at warm boundary temperatures of 164K and 305K, respectively. When compared to the performance for a traditional MLI system, a 60% reduction in orbital heat leak or boiloff was measured. Overall, the MHTB TCS demonstrated satisfactory performance for all mission phases required of a cryogenic upper stage.

Hastings, Leon↗

Membrane Separation of Gases From The Martian Atmosphere

A test bed has been constructed to test membrane modules for separation of gases under temperature and pressure conditions normally encountered on the surface of Mars. The test bed allows independent control of (1) feed flow rates, (2) feed composition, (3) feed pressure, (4) permeate pressure, and (5) operating temperature. Preliminary data obtained at a nominal feed pressure of 760 torr and permeate pressure of 10 torr has demonstrated the ability of one membrane module to operate at temperatures as low as -70 C. At temperatures below -40 C, however, significant loss of carbon dioxide and argon was observed, probably indicating condensation at the relatively high pressure used. As expected, permeation flow rates decreased with decreasing temperature, the flow at -30 C approximately 37% of the value at +23 C. Values of permeability for individual gas components showed similar decreases with decreasing temperature, but permeability ratios changed significantly. For example, the ratio of the permeabilities of carbon dioxide and nitrogen increased from 2.6 at 23 C to 5.6 at -30 C. Additional data at lower operating pressures and temperatures must be obtained in order to optimize design of a usable separation system.

Jennings, Paul A.↗

Membrane Separation of Gases from the Martian Atmosphere

A test bed has been constructed to test membrane modules for separation of gases under temperature and pressure conditions normally encountered on the surface of Mars. The test bed allows independent control of: (1) feed flow rates, (2) feed composition, (3) feed pressure, (4) permeate pressure, and (5) operating temperature. Preliminary data obtained at a nominal feed pressure of 760 torr and permeate pressure of 10 torr has demonstrated the ability of one membrane module to operate at temperatures as low as -70 C. At temperatures below -40 C, however, significant loss of carbon dioxide and argon was observed, probably indicating condensation at the relatively high pressure used. As expected, permeation flow rates decreased with decreasing temperature, the flow at -30 C approximately 37% of the value at +23 C. Values of permeability for individual gas components showed similar decreases with decreasing temperature, but permeability ratios changed significantly. For example, the ratio of the permeabilities of carbon dioxide and nitrogen increased from 2.6 at 23 C to 5.6 at -30 C. Additional data at lower operating pressures and temperatures must be obtained in order to optimize design of a usable separation system.

Jennings, Paul A.↗

Final Design for Thermal/Epithermal eXperiments (TEX) with Absorbers to Provide Validation Benchmarks for Y-12 Electrorefining Facility

One of the main goals of the Thermal/Epithermal eXperiments (TEX) project is to use existing Nuclear Criticality Safety Program (NCSP) assets to create critical experiment plutonium and uranium test beds for materials important to criticality safety that have insufficient benchmark evaluations. The plutonium test bed experiments were completed in 2018 and are published in the 2020 edition of the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The uranium test bed assemblies were measured in 2020, with benchmark preparation underway.

42 ENGINEERING↗

Final Design for Thermal/Epithermal eXperiments (TEX) with Lithium Absorbers to Provide Validation Benchmarks for Y-12 Electrorefining Facility (IER 575, CED-2 Report)

One of the main goals of the Thermal/Epithermal eXperiments (TEX) project is to use existing Nuclear Criticality Safety Program (NCSP) assets to create critical experiment plutonium and uranium test beds for materials important to criticality safety that have insufficient benchmark evaluations. The plutonium test bed experiments were completed in 2018 and are published in the 2020 edition of the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The uranium test bed assemblies were completed in 2023 and accepted in the 2024 edition of the ICSBEP Handbook.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Extended Bandwidth Spread Spectrum Time Domain Reflectometry Cable Test for Thermal Aging, Low Resistance Fault, and Water Detection

In 2022, researchers at Pacific Northwest National Laboratory (PNNL) used the Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable and motor test bed to characterize spread spectrum time domain reflectometry (SSTDR) and compare the responses of an SSTDR instrument to those of a frequency domain reflectometry (FDR) instrument. Results showed both techniques could detect and locate cable anomalies such as phase-to-phase low resistance and shorts, thermal insulation damage, mechanical insulation damage, and the presence or absence of water in some conditions. The SSTDR tests used a commercial instrument provided by LiveWire Innovations Inc. This commercial instrument performed tests at 6, 12, 24, and 48 MHz bandwidth. The results of these tests were compared to FDR tests where bandwidths could be extended up to 1.3 GHz, although the best responses for cable tests were from 100 to 500 MHz. Lower bandwidth signals can propagate better along the cable while higher bandwidths have higher resolution for impedance change reflections allowing more precise indication of location and separation of anomalies. The 2022 research found that FDR responses were clearer than SSTDR and speculated that a higher bandwidth SSTDR could more successfully detect and locate cable anomalies. One advantage of the SSTDR system investigated was that it was designed for energized online use up to 1,000 volts, which may be a significant advantage for nuclear power plant use. The LiveWire SSTDR instrument is an established product in the rail and aircraft industry and updating the SSTDR hardware parameters is difficult to justify without more conclusive testing. Therefore, a software adjustable laboratory SSTDR instrument was developed by PNNL and was used to test extended bandwidth SSTDR cable tests. Within the ARENA test bed, 42 cable conditions were tested with the PNNL SSTDR, FDR, and the LiveWire SSTDR—each operating at four different bandwidths. Observations and conclusions regarding the relative performance of the three instruments over different bandwidths are note below. Responses of the PNNL SSTDR (at 50 MHz) and the LiveWire SSTDR (at 48 MHz) were similar. The PNNL SSTDR higher frequency bandwidths behaved as expected showing sharper peaks and higher noise. This validated the PNNL SSTDR as a reasonable implementation of the SSTDR technology. Lower bandwidth SSTDR responses (particularly 6 and 12 MHz) may have increased value for use within longer cables but were not particularly effective at identifying anomalous cable behavior in the 100 ft cables tested here. The higher bandwidths of the PNNL SSTDR (50, 100, 200, and 400 MHz) did not provide substantially clearer cable reflectometry responses, but having the higher frequency responses available did add to the cable test evaluation. Strong responses to shorts and low impedance faults between phases were particularly evident in the higher bandwidth PNNL SSTDR and the FDR data. Measurements were repeatable, with similar responses obtained from a thermally aged cable for tests taken a month apart. Signal noise was affected in the unshielded cable by the local in-tray cable arrangement including proximity to metal edges and rungs of the cable tray. Foam isolation of the cable from the tray metal reduced in both FDR and SSTDR responses. Cable condition monitoring in nuclear power plants will likely benefit from both more informative off-line testing methods and from the development of on-line methods for continuous monitoring of cables in use. The LWRS-funded ARENA test bed was a valuable resource for this development and direct comparison of nuclear electrical cable condition monitoring technologies. Test results are targeted to guide industry advancement of testing and monitoring tools for cable aging management.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Situational Awareness of Grid Anomalies (SAGA)

The modern power industry becomes more vulnerable to cyber events due to the growing interconnectivity, interdependence, and complexity of the electric power grid. High-fidelity modeling and simulation tools that support the preventative risk analysis on potential cyber-relevant events is essential for ensuring the situational awareness of the system operator as it provides an inexpensive and risk-free environment to test the system responses under various cyber-relevant events and hereby can support research on cyber anomaly detection, optimal protective resource allocation, and mitigation measures. In this webinar, we will share NREL's cybersecurity research capabilities by highlighting the development of a scalable cyber-physical event test bed and demonstration with real hardware in the loop. The developed cyber-physical event test bed is backboned by an integrated transmission, distribution, and communication dynamic co-simulation framework and a plug-and-play cyber event generation module. It is designed to be modular and compatible with parallel computing, and thereby supports large-scale system simulations at an affordable computation cost. The test bed can capture millisecond-to-minutes dynamic frequency and voltage responses under cyber events from the bulk transmission system to the active distribution systems and distributed energy resources at the grid edge.

co-simulation↗

Study Of Radiation Effects Electronics at Atmospheric Altitudes

A test bed for the in situ evaluation of electronic devices for high altitude aircraft was developed. A prototype of the test bed, suitable for operation on a research aircraft, was built and readied for ground tests. The principle investigator established a working relationship with the Project APEX team at Dryden with the intent of flying the test bed "piggyback" on an Project APEX balloon in 1998. Contact was also established with NASA contractors charged with operating the ER-2 aircraft now at Dryden.

Wilkins, Richard↗

VERDEX: A virtual environment demonstrator for remote driving applications

One of the key areas of the National Advanced Robotics Centre's enabling technologies research program is that of the human system interface, phase 1 of which started in July 1989 and is currently addressing the potential of virtual environments to permit intuitive and natural interactions between a human operator and a remote robotic vehicle. The aim of the first 12 months of this program (to September, 1990) is to develop a virtual human-interface demonstrator for use later as a test bed for human factors experimentation. This presentation will describe the current state of development of the test bed, and will outline some human factors issues and problems for more general discussion. In brief, the virtual telepresence system for remote driving has been designed to take the following form. The human operator will be provided with a helmet-mounted stereo display assembly, facilities for speech recognition and synthesis (using the Marconi Macrospeak system), and a VPL DataGlove Model 2 unit. The vehicle to be used for the purposes of remote driving is a Cybermotion Navmaster K2A system, which will be equipped with a stereo camera and microphone pair, mounted on a motorized high-speed pan-and-tilt head incorporating a closed-loop laser ranging sensor for camera convergence control (currently under contractual development). It will be possible to relay information to and from the vehicle and sensory system via an umbilical or RF link. The aim is to develop an interactive audio-visual display system capable of presenting combined stereo TV pictures and virtual graphics windows, the latter featuring control representations appropriate for vehicle driving and interaction using a graphical 'hand,' slaved to the flex and tracking sensors of the DataGlove and an additional helmet-mounted Polhemus IsoTrack sensor. Developments planned for the virtual environment test bed include transfer of operator control between remote driving and remote manipulation, dexterous end effector integration, virtual force and tactile sensing (also the focus of a current ARRL contract, initially employing a 14-pneumatic bladder glove attachment), and sensor-driven world modeling for total virtual environment generation and operator-assistance in remote scene interrogation.

Stone, Robert J.↗

An expert system executive for automated assembly of large space truss structures

Langley Research Center developed a unique test bed for investigating the practical problems associated with the assembly of large space truss structures using robotic manipulators. The test bed is the result of an interdisciplinary effort that encompasses the full spectrum of assembly problems - from the design of mechanisms to the development of software. The automated structures assembly test bed and its operation are described, the expert system executive and its development are detailed, and the planned system evolution is discussed. Emphasis is on the expert system implementation of the program executive. The executive program must direct and reliably perform complex assembly tasks with the flexibility to recover from realistic system errors. The employment of an expert system permits information that pertains to the operation of the system to be encapsulated concisely within a knowledge base. This consolidation substantially reduced code, increased flexibility, eased software upgrades, and realized a savings in software maintenance costs.

Allen, Cheryl L.↗

Space Radiation Shielding Studies for Astronaut and Electronic Component Risk Assessment

The dosimetry component of the Center for Radiation Engineering and Science for Space Exploration (CRESSE) will design, develop and characterize the response of a suite of radiation detectors and supporting instrumentation and electronics with three primary goals that will: (1) Use established space radiation detection systems to characterize the primary and secondary radiation fields existing in the experimental test-bed zones during exposures at particle accelerator facilities. (2) Characterize the responses of newly developed space radiation detection systems in the experimental test-bed zones during exposures at particle accelerator facilities, and (3) Provide CRESSE collaborators with detailed dosimetry information in experimental test-bed zones.

Fuchs, Jordan Robert↗

Common Practice Lightning Strike Protection Characterization Technique to Quantify Damage Mechanisms on Composite Substrates

To support FAA certification airworthiness standards, composite substrates are subjected to lightning direct-effect electrical waveforms to determine performance characteristics of the lightning strike protection (LSP) conductive layers used to protect composite substrates. Test results collected from independent LSP studies are often incomparable due to variability in test procedures & applied practices at different organizations, which impairs performance correlations between different LSP data sets. Under a NASA supported contract, The Boeing Company developed technical procedures and documentation as guidance in order to facilitate a test method for conducting universal common practice lightning strike protection test procedures. The procedures obtain conformity in future lightning strike protection evaluations to allow meaningful performance correlations across data sets. This universal common practice guidance provides the manufacturing specifications to fabricate carbon fiber reinforced plastic (CFRP) test panels, including finish, grounding configuration, and acceptable methods for pretest nondestructive inspection (NDI) and posttest destructive inspection. The test operations guidance elaborates on the provisions contained in SAE ARP5416 to address inconsistencies in the generation of damage protection performance data, so as to provide for maximum achievable correlation across capable lab facilities. In addition, the guidance details a direct effects test bed design to aid in quantification of the multi-physical phenomena surrounding a lightning direct attachment supporting validation data requirements for the development of predictive computational modeling. The lightning test bed is designed to accommodate a repeatable installation procedure to secure the test panel and eliminate test installation uncertainty. It also facilitates a means to capture the electrical waveform parameters in 2 dimensions, along with the mechanical displacement and thermal heating parameters which occur during lightning attachment. Following guidance defined in the universal common practice LSP test documents, protected and unprotected CFRP panels were evaluated at 20, 40 and 100KAmps. This report presents analyzed data demonstrating the scientific usefulness of the common practice approach. Descriptions of the common practice CFRP test articles, LSP test bed fixture, and monitoring techniques to capture the electrical, mechanical and thermal parameters during lightning attachment are presented here. Two methods of measuring the electrical currents were evaluated, inductive current probes and a newly developed fiberoptic sensor. Two mechanical displacement methods were also examined, optical laser measurement sensors and a digital imaging correlation camera system. Recommendations are provided to help users implement the common practice test approach and obtain LSP test characterizations comparable across data sets.

Szatkowski, George N.↗

Reciprocating Feed System Development Status

The reciprocating feed system (RFS) is an alternative means of providing high pressure propellant flow at low cost and system mass, with high fail-operational reliability. The RFS functions by storing the liquid propellants in large, low-pressure tanks and then expelling each propellant through two or three small, high-pressure tanks. Each RFS tank is sequentially filled, pressurized, expelled, vented, and refilled so as to provide a constant, or variable, mass flow rate to the engine. This type of system is much lighter than a conventional pressure fed system in part due to the greatly reduced amount of inert tank weight. The delivered payload for an RFS is superior to that of conventional pressure fed systems for conditions of high total impulse and it is competitive with turbopump systems, up to approximately 2000 psi. An advanced version of the RFS uses autogenous pressurization and thrust augmentation to achieve higher performance. In this version, the pressurization gases are combusted in a small engine, thus making the pressurization system, in effect, part of the propulsion system. The RFS appears to be much less expensive than a turbopump system, due to reduced research and development cost and hardware cost, since it is basically composed of small high- pressure tanks, a pressurization system, and control valves. A major benefit is the high reliability fail-operational mode; in the event of a failure in one of the three tank-systems, it can operate on the two remaining tanks. Other benefits include variable pressure and flow rates, ease of engine restart in micro-gravity, and enhanced propellant acquisition and control under adverse acceleration conditions. We present a system mass analysis tool that accepts user inputs for various design and mission parameters and calculates such output values payload and vehicle weights for the conventional pressure fed system, the RFS, the Autogenous Pressurization Thrust Augmentation (APTA) RFS, and turbopump systems. Using this tool, a preliminary design of a representative crew exploration vehicle (CEV) has been considered. The design parameters selected for a representative system were modeled after the orbital maneuvering system (OMS) on the Shuttle Orbiter, with an increase of roughly a factor of ten in the delta- V capability and a greater thrust (30,000 lbs, vs. 12,000 lbs). Both storable and cryogenic propellants were considered. Results show that a RFS is a low mass alternative to conventional pressure fed systems, with a substantial increase in payload capability and that it is weight-competitive with turbopump systems at low engine pressure (a few hundred psi); at high engine pressures, the APTA RFS appears to offer the highest payload. We also present the status of the RFS test bed fabrication, assembly, and checkout. This test bed is designed to provide flow rates appropriate for engines in the roughly 10,000 to 30,000 lb thrust range.

Trewek, Mary↗

Integrated System Health Management (ISHM) Technology Demonstration Project Final Report

Integrated System Health Management (ISHM) is an essential capability that will be required to enable upcoming explorations mission systems such as the Crew Exploration Vehicle (CEV) and Crew Launch Vehicle (CLV), as well as NASA aeronautics missions. However, the lack of flight experience and available test platforms have held back the infusion by NASA Ames Research Center (ARC) and the Jet Propulsion Laboratory (JPL) of ISHM technologies into future space and aeronautical missions. To address this problem, a pioneer project was conceived to use a high-performance aircraft as a low-cost proxy to develop, mature, and verify the effectiveness of candidate ISHM technologies. Given the similarities between spacecraft and aircraft, an F/A-18 currently stationed at Dryden Flight Research Center (DFRC) was chosen as a suitable host platform for the test bed. This report describes how the test bed was conceived, how the technologies were integrated on to the aircraft, and how these technologies were matured during the project. It also describes the lessons learned during the project and a forward path for continued work.

Mackey, Ryan↗

The EGS Collab Project: Learnings from Experiment 1

The primary objective of the EGS Collab Project sponsored by DOE is to increase the understanding needed to efficiently implement enhanced geothermal systems (EGS). One goal of the EGS Collab project is to create a collaborative research environment in which to study stimulation of crystalline rock at the 10 meter scale. Key to this effort is the collection of high quality data to allow comparison to numerical coupled process models in an effort to build confidence in the codes and modeling techniques used. In response to this, the EGS Collab team has created an underground test bed at the Sanford Underground Research Facility (SURF) in Lead SD at a depth of approximately 1.5 km to examine hydraulic fracturing (Experiment 1). We are currently designing a second test bed aimed at investigating shear stimulation (Experiment 2). At the Experiment 1 location, we have characterized our host rock using laboratory testing and numerous field-based geophysical and geological techniques, and created a well-instrumented test bed to allow us to carefully monitor stimulation events and flow tests. In addition to the installed geophysical sensors, we have used tracer tests, differences in the ambient microbial communities at flow collection locations, and cold water injection to inform us about dynamic flow pathways. In Experiment 1, we have hydraulically stimulated the host rock in a number times at several locations in one well, creating new fractures that connect to existing fractures between the injection and production boreholes. We have performed long-term ambient and chilled water injection tests as an analog to EGS, and have monitored system changes resulting from these water injections through geophysical monitoring, flow and pressure measurements, tracer tests, and microbiology. Here, we summarize the tests performed, issues identified including poroelastic and thermoelastic effects, Joule-Thomson effects, restarting effects, indications of flow channeling, and the primary learnings from Experiment 1.

Enhanced Geothermal Systems, EGS Collab, stimulati↗