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DOE OSTI2021

Advancements Toward ASME Nuclear Code Case for Compact Heat Exchangers

Our research team proposes to advance the state of the ASME section III code (nuclear service) for Compact Heat Exchangers (CHX). This work will improve the technical state of CHXs and lay the foundation necessary for these heat exchangers to be certified for use in nuclear service. During the course of this work, we will advance the understanding of the performance, integrity, and lifetime of the CHXs for use in any industrial application, making their use more attractive and accessible to the industry. We will do this by developing qualification and inspection procedures that utilize Non-destructive evaluation (NDE) and advanced in-service inspection techniques, with insight from the industrial utility leader EPRI. We have enlisted colleagues at MPR Associates (MPR), an elite nuclear code consulting firm, who are experts on the ASME section III code and who, with input from members of the ASME section III committee, will direct the testing and help develop a series of documents that define the rules and regulations for use of the CHX. Colleagues at North Carolina State University (NCSU) and Oregon State University (OSU) will conduct extensive tensile, creep, and fatigue experiments on diffusion bonded samples (manufactured by US-based Vacuum Process engineering) along with modeling using the elastic perfectly plastic assumptions and comprehensive full inelastic finite element analysis (FEA). This work will allow analysis by design and confidence in the strength of different internal structures. To ensure industry acceptance and long term confidence, team members at the University of Wisconsin–Madison (UW), University of Michigan (UM), Georgia Tech (GT), and the University of Idaho (UI) will extensively test prototypic heat exchangers manufactured by US-based manufactures CompRex and Vacuum Process Engineering (VPE), a leader in the development of advanced CHX. This testing will include the use of various working fluids (salt, sodium, helium, and sCO2) to evaluate operational issues as well as structural integrity under the most severe conditions. Post-test analysis of the tested CHXs coupled with pre/in-service/post NDE (ultrasonic and radiography) led by the Electric Power Research Institute (EPRI) will be incorporated into the development of the rules and regulations for their use in nuclear service.

42 ENGINEERING↗

NASA NTRS1995

Centrifugal and Axial Pump Design and Off-Design Performance Prediction

A meanline pump-flow modeling method has been developed to provide a fast capability for modeling pumps of cryogenic rocket engines. Based on this method, a meanline pump-flow code PUMPA was written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The design-point rotor efficiency and slip factors are obtained from empirical correlations to rotor-specific speed and geometry. The pump code can model axial, inducer, mixed-flow, and centrifugal pumps and can model multistage pumps in series. The rapid input setup and computer run time for this meanline pump flow code make it an effective analysis and conceptual design tool. The map-generation capabilities of the code provide the information needed for interfacing with a rocket engine system modeling code. The off-design and multistage modeling capabilities of PUMPA permit the user to do parametric design space exploration of candidate pump configurations and to provide head-flow maps for engine system evaluation.

Veres, Joseph P.↗

NASA NTRS1984

A real-time, portable, microcomputer-based jet engine simulator

Modern piloted flight simulators require detailed models of many aircraft components, such as the airframe, propulsion system, flight deck controls and instrumentation, as well as motion drive and visual display systems. The amount of computing power necessary to implement these systems can exceed that offered by dedicated mainframe computers. One approach to this problem is through the use of distributed computing, where parts of the simulation are assigned to computing subsystems, such as microcomputers. One such subsystem, such as microcomputers. One such subsystem, a real-time, portable, microcomputer-based jet engine simulator, is described in this paper. The simulator will be used at the NASA Ames Vertical Motion Simulator facility to perform calculations previously done on the facility's mainframe computer. The mainframe will continue to do all other system calculations and will interface to the engine simulator through analog I/0. The engine simulator hardware includes a 16-bit microcomputer and floating-point coprocessor. There is an 8 channel analog input board and an 8 channel analog output board. A model of a small turboshaft engine/control is coded in floating-point FORTRAN. The FORTRAN code and a data monitoring program run under the control of an assembly language real-time executive. The monitoring program allows the user to isplay and/or modify simulator variables on-line through a data terminal. A dual disk drive system is used for mass storage of programs and data. The CP/M-86 operating system provides file management and overall system control. The frame time for the simulator is 30 milliseconds, which includes all analog I/0 operations.

Blech, R. A.↗

DOE OSTI2019

Uncertainty Quantification of Microstructural Material Variability Effects

This project has developed models of variability of performance to enable robust design and certification. Material variability originating from microstructure has significant effects on component behavior and creates uncertainty in material response. The outcomes of this project are uncertainty quantification (UQ) enabled analysis of material variability effects on performance and methods to evaluate the consequences of microstructural variability on material response in general. Material variability originating from heterogeneous microstructural features, such as grain and pore morphologies, has significant effects on component behavior and creates uncertainty around performance. Current engineering material models typically do not incorporate microstructural variability explicitly, rather functional forms are chosen based on intuition and parameters are selected to reflect mean behavior. Conversely, mesoscale models that capture the microstructural physics, and inherent variability, are impractical to utilize at the engineering scale. Therefore, current efforts ignore physical characteristics of systems that may be the predominant factors for quantifying system reliability. To address this gap we have developed explicit connections between models of microstructural variability and component/system performance. Our focus on variability of mechanical response due to grain and pore distributions enabled us to fully probe these influences on performance and develop a methodology to propagate input variability to output performance. This project is at the forefront of data-science and material modeling. We adapted and innovated from progressive techniques in machine learning and uncertainty quantification to develop a new, physically-based methodology to address the core issues of the Engineering Materials Reliability (EMR) research challenge in modeling constitutive response of materials with significant inherent variability and length-scales.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Development of Anabaena 33047, a Fast-Growing N 2 -Fixing Cyanobacterium, as a Carbon Neutral Bioproduction Platform

Cyanobacteria, oxygenic photosynthetic prokaryotes, are emerging as promising platforms for cost effective conversion of sunlight and CO 2 into high value end products. Anabaena sp. ATCC 33047, a heterocystous cyanobacterium, stands out in this category of fast-growing cyanobacteria for its ability to utilize atmospheric N 2 in addition to CO 2 and generate biomass at unprecedented rates. Developing such a strain as a chassis can eliminate the need for fixed nitrogen in bioproduction systems, a significant step towards replacement of petroleum derived products. Our work aimed to develop Anabaena 33047 into such a bioproduction platform. Despite its many appealing traits, Anabaena 33047 remained largely unexplored due to its recalcitrance to any genetic manipulation. During this project, we have developed a method that has enabled targeted genome modification of this strain. We also constructed a genome scale metabolic model i AnC892, which captures the diazotrophic life cycle of Anabaena 33047 by accounting for both vegetative and heterocyst cell types. The model provided insight into the importance of light dependent electron transport in the heterocyst and revealed pathway combinations that can supply reducing equivalents and ATP in the appropriate ratio for optimal N2 fixation. To validate the existing metabolic models and to have a better understanding of the metabolism of Anabaena 33047 under different growth conditions, we performed a series of stable-isotope tracing experiments and quantified metabolic fluxes using state-of-the-art tools for 13C-metabolic flux analysis. Using our novel engineering strategy and based on our model predictions, we performed targeted deletion in the strain and generated a mutant with modified light harvesting properties in heterocysts. The mutant exhibited better light utilization and increased rates of nitrogen fixation. Overall, this project has laid the foundation for developing the non-model cyanobacterium Anabaena 33047 into a highly efficient chassis for conversion of solar energy, atmospheric CO 2 and N 2 into high value bio products.

09 BIOMASS FUELS↗

NASA NTRS1995

Evolutionary Development of the Simulation by Logical Modeling System (SIBYL)

Through the evolutionary development of the Simulation by Logical Modeling System (SIBYL) we have re-engineered the expensive and complex IBM mainframe based Long-term Hardware Projection Model (LHPM) to a robust cost-effective computer based mode that is easy to use. We achieved significant cost reductions and improved productivity in preparing long-term forecasts of Space Shuttle Main Engine (SSME) hardware. The LHPM for the SSME is a stochastic simulation model that projects the hardware requirements over 10 years. SIBYL is now the primary modeling tool for developing SSME logistics proposals and Program Operating Plan (POP) for NASA and divisional marketing studies.

Wu, Helen↗

DOE OSTI2021

Assessment of Turbulent Combustion Models for Simulating Prechamber Ignition in a Natural Gas Engine

Lean combustion is a promising strategy to increase thermal efficiency in an internal combustion engine, by exploiting a favorable specific heat ratio of the fresh mixture while simultaneously suppressing the heat losses to the cylinder wall. However, unstable ignition and slow flame propagation at fuel-lean conditions lead to large cycle-to-cycle variability and limit the high-efficiency engine operating range. Prechamber ignition is considered an effective concept to extend the lean operating limit, by providing spatially distributed ignition with multiple turbulent flame-jets and enabling a faster combustion rate compared to the conventional spark ignition approach. From a numerical modeling standpoint to date science base and available simulation tools are inadequate to properly understand and predict the combustion processes in prechamber ignited engines. In this paper, conceptually different Reynolds-averaged Navier–Stokes (RANS) combustion models widely adopted in the engine modeling community are used to simulate the ignition and combustion processes in a medium-duty natural gas engine with a prechamber spark-ignition system. Here, a flamelet-based turbulent combustion model, i.e., G-equation, and a multizone well-stirred reactor model are employed for this modeling study. Simulation results are compared with experimental data in terms of in-cylinder pressure and heat release rate. Finally, the analysis of the performance of the two models is carried out to highlight the strengths and limitations of the two evaluated approaches.

42 ENGINEERING↗

NASA NTRS1995

Integrating Reliability Analysis with a Performance Tool

A large number of commercial simulation tools support performance oriented studies of complex computer and communication systems. Reliability of these systems, when desired, must be obtained by remodeling the system in a different tool. This has obvious drawbacks: (1) substantial extra effort is required to create the reliability model; (2) through modeling error the reliability model may not reflect precisely the same system as the performance model; (3) as the performance model evolves one must continuously reevaluate the validity of assumptions made in that model. In this paper we describe an approach, and a tool that implements this approach, for integrating a reliability analysis engine into a production quality simulation based performance modeling tool, and for modeling within such an integrated tool. The integrated tool allows one to use the same modeling formalisms to conduct both performance and reliability studies. We describe how the reliability analysis engine is integrated into the performance tool, describe the extensions made to the performance tool to support the reliability analysis, and consider the tool's performance.

Nicol, David M.↗

NASA NTRS1976

Analysis of rocket engine injection combustion processes

A critique is given of the JANNAF sub-critical propellant injection/combustion process analysis computer models and application of the models to correlation of well documented hot fire engine data bases. These programs are the distributed energy release (DER) model for conventional liquid propellants injectors and the coaxial injection combustion model (CICM) for gaseous annulus/liquid core coaxial injectors. The critique identifies model inconsistencies while the computer analyses provide quantitative data on predictive accuracy. The program is comprised of three tasks: (1) computer program review and operations; (2) analysis and data correlations; and (3) documentation.

Salmon, J. W.↗

NASA NTRS1994

Axial and centrifugal pump meanline performance analysis

A meanline pump flow modeling method has been developed to provide a fast capability for modeling pumps of cryogenic rocket engines. Based on this method, a meanline pump flow code (PUMPA) has been written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The design point rotor efficiency is obtained from empirically derived correlations of loss to rotor specific speed. The rapid input setup and computer run time for the meanline pump flow code makes it an effective analysis and conceptual design tool. The map generation capabilities of the PUMPA code provide the information needed for interfacing with a rocket engine system modeling code.

Veres, Joseph P.↗

NASA NTRS2002

Global Reference Atmospheric Model and Trace Constituents

Global Reference Atmospheric Model (GRAM-99) is an engineering-level model of the Earth's atmosphere. It provides both mean values and perturbations for density, temperature, pressure, and winds, as well as monthly- and geographically-varying trace constituent concentrations. From 0-27 km, thermodynamics and winds are based on National Oceanic and Atmospheric Administration Global Upper Air Climatic Atlas (GUACA) climatology. Above 120 km, GRAM is based on the NASA Marshall Engineering Thermosphere (MET) model. In the intervening altitude region, GRAM is based on Middle Atmosphere Program (MAP) climatology that also forms the basis of the 1986 COSPAR Intemationa1 Reference Atmosphere (CIRA). MAP data in GRAM are augmented by a specially-derived longitude variation climatology. Atmospheric composition is represented in GRAM by concentrations of both major and minor species. Above 120 km, MET provides concentration values for N2, O2, Ar, O, He, and H. Below 120 km, species represented also include H2O, O3, N2O, CO, CH, and CO2. Water vapor in GRAM is based on a combination of GUACA, Air Force Geophysics Laboratory (AFGL), and NASA Langley Research Center climatologies. Other constituents below 120 km are based on a combination of AFGL and h4AP/CIRA climatologies. This report presents results of comparisons between GRAM Constituent concentrations and those provided by the Naval Research Laboratory (NRL) climatology of Summers (NRL,/MR/7641-93-7416, 1993). GRAM and NRL concentrations were compared for seven species (CH4, CO, CO2, H2O, N2O, O2, and O3) for months January, April, July, and October, over height range 0-115 km, and latitudes -90deg to + 90deg at 10deg increments. Average GRAM-NRL correlations range from 0.878 (for CO) to 0.975 (for O3), with an average over all seven species of 0.936 (standard deviation 0.049).

Justus, C.↗

NASA NTRS2004

Earth GRAM-99 and Trace Constituents

Global Reference Atmospheric Model (GRAM-99) is an engineering-level model of Earth's atmosphere. It provides both mean values and perturbations for density, temperature, pressure, and winds, as well as monthly- and geographically-varying trace constituent concentrations. From 0-27 km, GRAM thermodynamics and winds are based on National Oceanic and Atmospheric Administration Global Upper Air Climatic Atlas (GUACA) climatology. Above 120 km, GRAM is based on the NASA Marshall Engineering Thermosphere (MET) model. In the intervening altitude region, GRAM is based on Middle Atmosphere Program (MAP) climatology that also forms the basis of the 1986 COSPAR International Reference Atmosphere (CIRA). Atmospheric composition is represented in GRAM by concentrations of both major and minor species. Above 120 km, MET provides concentration values for N2, O2, Ar, O, He, and H. Below 120 km, species represented also include H2O, O3, N2O, CO, CH4, and CO2. At COSPAR 2002 a comparison was made between GRAM constituents below 120 km and those provided by Naval Research Laboratory (NRL) climatology. No current need to update GRAM constituent climatology in that height range was identified. This report examines GRAM (MET) constituents between 100 and 1000 km altitudes. Discrepancies are noted between GRAM (MET) constituent number densities and mass density or molecular weight. Near 110 km altitude, there is up to about 25% discrepancy between MET number density and mass density (with mass density being valid and number densities requiring adjustment). Near 700 km altitude there is also up to about 25% discrepancy between MET number density and mean molecular weight (with molecular weight requiring adjustment). In neither case are MET mass density estimates invalidated. These discrepancies have been traced to MET subroutines SLV (which affects 90-170 km height range) and SLVH (which affects helium above 440 km altitude). With these discrepancies corrected, results are presented to illustrate GRAM (MET) constituent mole fractions in terms of height-latitude cross sections from 100 to 1000 km altitude, and latitude-longitude 'maps' at 450 km (approximate height of International Space Station). Plans are discussed for an update of MET (and GRAM) to correct these constituent inconsistencies and to incorporate several new thermospheric model features.

Justus, C. G.↗

NASA NTRS2001

A Hybrid Neural Network-Genetic Algorithm Technique for Aircraft Engine Performance Diagnostics

In this paper, a model-based diagnostic method, which utilizes Neural Networks and Genetic Algorithms, is investigated. Neural networks are applied to estimate the engine internal health, and Genetic Algorithms are applied for sensor bias detection and estimation. This hybrid approach takes advantage of the nonlinear estimation capability provided by neural networks while improving the robustness to measurement uncertainty through the application of Genetic Algorithms. The hybrid diagnostic technique also has the ability to rank multiple potential solutions for a given set of anomalous sensor measurements in order to reduce false alarms and missed detections. The performance of the hybrid diagnostic technique is evaluated through some case studies derived from a turbofan engine simulation. The results show this approach is promising for reliable diagnostics of aircraft engines.

Kobayashi, Takahisa↗

NASA NTRS1991

Redesign of flight space shuttle main engine nozzle G-15 seal area based on the thermal analysis and flow models

The main objective is to understand the present sealing area response to environmental conditions of the supersonic turbulent combustion gases which has led to both stress rupture cracks and hot gas leakage. A review of the existing thermal analysis and flow modeling has been performed of the present design and seal alternatives have been suggested to possibly reduce or eliminate the hot gas flow recirculation problem and the associated seal cracking.

Mcdonald, Gary H.↗

NASA NTRS1992

Laboratory for Engineering Man/Machine Systems (LEMS): System identification, model reduction and deconvolution filtering using Fourier based modulating signals and high order statistics

Several important problems in the fields of signal processing and model identification, such as system structure identification, frequency response determination, high order model reduction, high resolution frequency analysis, deconvolution filtering, and etc. Each of these topics involves a wide range of applications and has received considerable attention. Using the Fourier based sinusoidal modulating signals, it is shown that a discrete autoregressive model can be constructed for the least squares identification of continuous systems. Some identification algorithms are presented for both SISO and MIMO systems frequency response determination using only transient data. Also, several new schemes for model reduction were developed. Based upon the complex sinusoidal modulating signals, a parametric least squares algorithm for high resolution frequency estimation is proposed. Numerical examples show that the proposed algorithm gives better performance than the usual. Also, the problem was studied of deconvolution and parameter identification of a general noncausal nonminimum phase ARMA system driven by non-Gaussian stationary random processes. Algorithms are introduced for inverse cumulant estimation, both in the frequency domain via the FFT algorithms and in the domain via the least squares algorithm.

Pan, Jianqiang↗

NASA NTRS2004

Adaptive model-based control systems and methods for controlling a gas turbine

Adaptive model-based control systems and methods are described so that performance and/or operability of a gas turbine in an aircraft engine, power plant, marine propulsion, or industrial application can be optimized under normal, deteriorated, faulted, failed and/or damaged operation. First, a model of each relevant system or component is created, and the model is adapted to the engine. Then, if/when deterioration, a fault, a failure or some kind of damage to an engine component or system is detected, that information is input to the model-based control as changes to the model, constraints, objective function, or other control parameters. With all the information about the engine condition, and state and directives on the control goals in terms of an objective function and constraints, the control then solves an optimization so the optimal control action can be determined and taken. This model and control may be updated in real-time to account for engine-to-engine variation, deterioration, damage, faults and/or failures using optimal corrective control action command(s).

Brunell, Brent Jerome↗

DOE OSTI2020

Assessment of turbulent combustion models for simulating pre-chamber ignition in a natural gas engine

Lean combustion in an internal combustion engine is a promising strategy to increase thermal efficiency by leveraging a more favorable specific heat ratio of the fresh mixture and simultaneously suppressing the heat losses to the cylinder wall. However, unstable ignition events and slow flame propagation at fuel-lean condition lead to high cycle-to-cycle variability and hence limit the high-efficiency engine operating range. Pre-chamber ignition is considered an effective concept to extend the lean operating limit, by providing spatially distributed ignition with multiple turbulent flame-jets and enabling faster combustion rate compared to the conventional spark ignition approach. From a numerical modeling perspective, to date, still the science base and available simulation tools are inadequate for understanding and predicting the combustion processes in pre-chamber ignited engines. In this paper, conceptually different RANS combustion models widely adopted in the engine modeling community were used to simulate the ignition and combustion processes in a medium-duty natural gas engine with a pre-chamber spark-ignition system. A flamelet-based turbulent combustion model, i.e., G-equation, and a multi-zone well-stirred reactor model were employed for the multi-dimensional study. Simulation results were compared with experimental data in terms of in-cylinder pressure and heat release rate. Finally, the analysis of the performance of the two models is carried out to highlight the strengths and limitations of the two formulations respectively.

combustion model evaluation↗

NASA NTRS1998

Model Based Autonomy for Robust Mars Operations

Space missions have historically relied upon a large ground staff, numbering in the hundreds for complex missions, to maintain routine operations. When an anomaly occurs, this small army of engineers attempts to identify and work around the problem. A piloted Mars mission, with its multiyear duration, cost pressures, half-hour communication delays and two-week blackouts cannot be closely controlled by a battalion of engineers on Earth. Flight crew involvement in routine system operations must also be minimized to maximize science return. It also may be unrealistic to require the crew have the expertise in each mission subsystem needed to diagnose a system failure and effect a timely repair, as engineers did for Apollo 13. Enter model-based autonomy, which allows complex systems to autonomously maintain operation despite failures or anomalous conditions, contributing to safe, robust, and minimally supervised operation of spacecraft, life support, In Situ Resource Utilization (ISRU) and power systems. Autonomous reasoning is central to the approach. A reasoning algorithm uses a logical or mathematical model of a system to infer how to operate the system, diagnose failures and generate appropriate behavior to repair or reconfigure the system in response. The 'plug and play' nature of the models enables low cost development of autonomy for multiple platforms. Declarative, reusable models capture relevant aspects of the behavior of simple devices (e.g. valves or thrusters). Reasoning algorithms combine device models to create a model of the system-wide interactions and behavior of a complex, unique artifact such as a spacecraft. Rather than requiring engineers to all possible interactions and failures at design time or perform analysis during the mission, the reasoning engine generates the appropriate response to the current situation, taking into account its system-wide knowledge, the current state, and even sensor failures or unexpected behavior.

Kurien, James A.↗