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DOE OSTI2017

Technical Requirements for Application of Operator Support Technology across Multiple Plant Systems

Argonne National Laboratory (ANL) and Idaho National Laboratory (INL) are jointly developing and evaluating operator aids to: (i) facilitate more timely response to plant faults and grid disturbances; (ii) achieve better management of plant upsets and improved operator performance; and (iii) ultimately improve nuclear plant safety, production, and cost management. The overall objective of the collaborative effort in this third and final year of the project was to conduct human performance tests using nuclear plant operators in the Human Systems Simulation Laboratory (HSSL) control room at INL to assess the value of a computerized operator support system (COSS) as an aid to the operator. This report describes the work performed by ANL. A companion report describes the work performed by INL and the results of the human performance tests.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Corrosion Behavior of Steels in Supercritical CO 2 for Power Cycle Applications

In order to understand issues with corrosion of heat exchanger materials in direct supercritical carbon dioxide (sCO 2 ) power cycles, a series of autoclave exposure experiments and electrochemical experiments have been conducted. Corrosion behaviors of 347H stainless steel and P91 martensitic-ferrtic steel in sCO 2 environment have been compared. In autoclave exposure tests performed at 50°C- 245°C and 80 bar. Mass change measurements, surface characterization, and corrosion product analysis have been conducted to understand the corrosion behavior of steels in sCO 2 containing H 2 O and O 2 . Electrochemical tests performed at room temperature and 50°C, a simulation environment of water condensation phase with dissolved CO 2 was prepared to evaluate the corrosion resistance of materials. From both types of experiments, generally 347H showed higher corrosion resistance than P91.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Excerpt from Oxygen Monitor Clean Testing Report Performed in 2010

The Rosemount X-STREAM Series X2GP is a paramagnetic oxygen analyzer with a 0-25% oxygen measurement range. It claims a drift less than 2% of span (0.10% volume oxygen) per week, and a response time of less than 5 seconds (for the analyzer to report 90% of a step change). Our test equipment was set-up such that the same gas was running through each oxygen analyzer at the same time. This allowed Calibration Error, Calibration Drift, and Loss of Power Testing to be run on all monitors at the same time, eliminating any variability between the analyzers from tolerances in the gas cylinder, ambient temperature, ambient pressure, test duration, etc. An APTech pressure regulator was placed on the gas cylinder manifold and a 23 psia Paroscientific pressure transducer measured the regulator’s outlet pressure. This did not give the inlet pressure on any one analyzer but outlet pressure from the manifold before the stream was split. The APTech pressure regulator was used to keep operating conditions consistent. A DWYER rotameter was installed on each oxygen monitor’s outlet piping. With the exception of Variation of Flow Rate Testing, the rotameter was left fully open for all testing. The flow rate through each oxygen monitor was controlled by a Swagelok needle valve that was installed on each analyzer’s inlet piping. Additionally, a filter was installed in the each monitor’s inlet piping to keep particles from the measurement cells and a Swagelok ball valve was installed on each monitor’s outlet piping to isolate each monitor between tests. No pumps were installed. Each of the cylinders used was at a pressure greater than ambient room barometric pressure. This pressure differential was used to move gas through the testing equipment. The flow rate through each analyzer was controlled by the Swagelok needle valve installed on each analyzer’s inlet piping. Finally, for all tests, a Paroscientific Digiquartz Barometer was used to measure ambient room barometric pressure and a Fluke Thermo-hygrometer was used to measure ambient room temperature.

47 OTHER INSTRUMENTATION↗

DOE OSTI2013

Full-Scale Testing of the Ambient Pressure, Acid-Dissolution Front-End Process for the Current Mo-99 Recovery Processes

The Global Threat Reduction Initiative (GTRI) Conversion Program is actively developing technologies for the conversion of civilian facilities using high enriched uranium (HEU) to low enriched uranium (LEU) fuels and targets. The conversion of conventional HEU targets to LEU for 99 Mo production requires approximately five times the uranium in a target to maintain the 99 Mo yield on a per target basis. Under GTRI, Argonne is developing two front-end options for current 99 Mo production processes to allow the use of LEU-foil targets. In both processes, the aim is to produce a front-end product that is compatible with current 99 Mo purification operations and will provide the same or higher yield of 99 Mo for the same number of irradiated targets. The two front-end processes under development as part of this project are (1) the dissolution of irradiated LEU foil (up to 250 g in a single batch) and nickel fission recoil barrier in nitric acid at ambient pressure and (2) the electrochemical dissolution of LEU foil in a series of steps that produces an alkaline (basic) solution feed for 99 Mo purification. This report describes the results of performance tests and design optimization of the ambient pressure, nitric acid dissolver system. The design, fabrication, and performance test planning for this system are described in more detail in previous reports (Jerden et al. 2011a,b, 2012). Full-scale demonstrations of both of the front-end processes using irradiated uranium foils are planned to be performed at Oak Ridge National Laboratory this fiscal year.

Jerden, James↗

NASA NTRS1993

X-Ray-Diffraction Tests Of Irradiated Electronic Devices: I

X-ray-diffraction tests performed on aluminum conductors in commercial HI1-507A complementary metal oxide/semiconductor (CMOS) integrated-circuit analog multiplexers, both before and after circuits exposed to ionizing radiation from Co(60) source, and after postirradiation annealing at ambient and elevated temperatures. Tests in addition to electrical tests performed to determine effects of irradiation and of postirradiation annealing on electrical operating characteristics of circuits. Investigators sought to determine whether relationship between effects of irradiation on devices and physical stresses within devices. X-ray diffraction potentially useful for nondestructive measurement of stresses.

Shaw, David C.↗

NASA NTRS1978

Low background focal plane array testing in the far infrared

A new long-wavelength infrared test facility is being developed to conduct proof-of-performance tests of focal plane arrays for the Infrared Astronomical Satellite (IRAS) telescope. This facility is believed to be unique in that it will calibrate full-sized arrays designed for the 5-120-micron region of the IR spectrum under simulated spaceflight conditions and at background levels as low as 8 million photons/sq cm-sec. Most of the tests will be performed in a main test chamber which contains a liquid helium shroud, blackbody sources, an arrangement to simulate zodiacal background, and spot scanning optics. A noncontaminating high-vacuum pumping system will be used to evacuate the chamber prior to cool-down to prevent molecular deposition. All housekeeping and focal plane signal outputs are multiplexed, digitized, and transmitted on high-speed data lines to a PDP-11/70 computer. The computer provides real-time displays on a color CRT terminal and stores data for subsequent reduction and hard copy output. An overview of the conceptual design and performance specifications of the test facility are given.

Iufer, E. J.↗

NASA NTRS2005

Testing of a Spray-bar Thermodynamic Vent System in Liquid Nitrogen

To support development of a microgravity pressure control capability for liquid oxygen, thermodynamic vent system (TVS) testing was conducted at Marshall Space Flight Center (MSFC) using liquid nitrogen (LN2) as a LOX simulant. The spray bar TVS hardware used was originally designed by the Boeing Company for testing in liquid hydrogen (LH2). With this concept, a small portion of the tank fluid is passed through a Joule-Thomson (J-T) device, and then through a longitudinal spray bar mixed-heat exchanger in order to cool the bulk fluid. To accommodate the larger mass flow rates associated with LN2, the TVS hardware was modified by replacing the recirculation pump with an LN2 compatible pump and replacing the J-T valve. The primary advantage of the spray-bar configuration is that tank pressure control can be achieved independent of liquid and vapor location, enhancing the applicability of ground test data to microgravity conditions. Performance testing revealed that the spray-bar TVS was effective in controlling tank pressure within a 6.89 kPa band for fill levels of 90%, 50%, and 25%. Tests were also conducted with gaseous helium (GHe) in the ullage. The TVS operated nominally with GHe in the ullage, with performance similar to the tests with gaseous nitrogen (GN2). Testing demonstrated that the spray-bar TVS design was flexible enough for use in two different propellants with minimal hardware modifications.

Flachbart, R. H.↗

DOE OSTI2013

Full-Scale Testing of the Ambient Pressure, Acid-Dissolution Front-End Process for the Current 99 Mo Recovery Processes

The Global Threat Reduction Initiative (GTRI) Conversion Program is actively developing technologies for converting civilian facilities that use high enriched uranium (HEU) to low enriched uranium (LEU) fuels and targets. The conversion of conventional HEU targets to LEU for the production of 99 Mo production requires approximately five times the uranium in a target to maintain the 99 Mo yield on a per-target basis. Under GTRI, Argonne National Laboratory (Argonne) is developing two frontend options for current 99 Mo production processes to allow the use of LEU-foil targets. In both processes, the aim is to produce a frontend product that is compatible with current 99 Mo purification operations and will provide the same or a higher yield of 99 Mo for the same number of irradiated targets. The two frontend processes under development as part of this project are (1) the dissolution of irradiated LEU foil (up to 250 g in a single batch) and nickel fission recoil barrier in nitric acid at ambient pressure; and (2) the electrochemical dissolution of LEU foil in series of steps that produces an alkaline (basic) solution feed for 99 Mo purification. This report describes results from performance tests and design optimization of the ambient pressure, nitric-acid-dissolver system. The design, fabrication, and performance test planning for this system are described in more detail in previous reports (Jerden et al. 2011a,b, 2012). Full-scale demonstrations of both of the frontend processes using irradiated uranium foils are planned to be performed at Oak Ridge National Laboratory this fiscal year.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

NASA NTRS2009

Cascade Distillation Subsystem Development: Progress Toward a Distillation Comparison Test

Recovery of potable water from wastewater is essential for the success of long-duration manned missions to the Moon and Mars. Honeywell International and a team from NASA Johnson Space Center (JSC) are developing a wastewater processing subsystem that is based on centrifugal vacuum distillation. The wastewater processor, referred to as the Cascade Distillation Subsystem (CDS), utilizes an innovative and efficient multistage thermodynamic process to produce purified water. The rotary centrifugal design of the system also provides gas/liquid phase separation and liquid transport under microgravity conditions. A five-stage subsystem unit has been designed, built, delivered and integrated into the NASA JSC Advanced Water Recovery Systems Development Facility for performance testing. A major test objective of the project is to demonstrate the advancement of the CDS technology from the breadboard level to a subsystem level unit. An initial round of CDS performance testing was completed in fiscal year (FY) 2008. Based on FY08 testing, the system is now in development to support an Exploration Life Support (ELS) Project distillation comparison test expected to begin in early 2009. As part of the project objectives planned for FY09, the system will be reconfigured to support the ELS comparison test. The CDS will then be challenged with a series of human-gene-rated waste streams representative of those anticipated for a lunar outpost. This paper provides a description of the CDS technology, a status of the current project activities, and data on the system s performance to date.

Callahan, M. R.↗

DOE OSTI2013

Design, analysis and testing of a parallel-kinematic high-bandwidth XY nanopositioning stage

This paper presents the design, analysis, and testing of a parallel-kinematic high-bandwidth XY nanopositioning stage driven by piezoelectric stack actuators. The stage is designed with two kinematic chains. In each kinematic chain, the end-effector of the stage is connected to the base by two symmetrically distributed flexure modules, respectively. Each flexure module comprises a fixed-fixed beam and a parallelogram flexure serving as two orthogonal prismatic joints. With the purpose to achieve high resonance frequencies of the stage, a novel center-thickened beam which has large stiffness is proposed to act as the fixed-fixed beam. The center-thickened beam also contributes to reducing cross-coupling and restricting parasitic motion. To decouple the motion in two axes totally, a symmetric configuration is adopted for the parallelogram flexures. Based on the analytical models established in static and dynamic analysis, the dimensions of the stage are optimized in order to maximize the first resonance frequency. Then finite element analysis is utilized to validate the design and a prototype of the stage is fabricated for performance tests. According to the results of static and dynamic tests, the resonance frequencies of the developed stage are over 13.6 kHz and the workspace is 11.2 μm × 11.6 μm with the cross-coupling between two axes less than 0.52%. It is clearly demonstrated that the developed stage has high resonance frequencies, a relatively large travel range, and nearly decoupled performance between two axes. For high-speed tracking performance tests, an inversion-based feedforward controller is implemented for the stage to compensate for the positioning errors caused by mechanical vibration. The experimental results show that good tracking performance at high speed is achieved, which validates the effectiveness of the developed stage.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1976

CO2 and humidity removal system for extended Shuttle missions - Equilibrium testing and performance analysis

In Shuttle orbiter cabins, lithium hydroxide (LiOH) canisters are currently planned to be used for CO2 adsorption and condensing heat exchangers for humidity control. In this paper a more effective CO2 and humidity removal method is proposed by replacing the LiOH component with HS-C adsorbent (a polyethylenimine coated acrylic ester), thus eliminating the low temperature constraints on the active thermal control system. Since the adsorption of CO2 and H2O are reversible, a double bed configuration operating cyclicly is planned to provide continuous atmospheric control. Apparatus and the experimental procedure to test the adsorption equilibrium are described and some of the indicative results, tabulated by computers, are presented with the help of exponential expressions and differential equations. By using a computer model of the Shuttle HS-C system, performance predictions are made.

Davis, S. H.↗

NASA NTRS1974

A 727/JT8D-100 series engine exhaust system propulsion performance model test

The results are presented from testing one-eighth scale models of the Pratt and Whitney aircraft reference and Boeing nozzles for the JT8D-100 series mixed flow engines. The objective of the test was to obtain the nozzle velocity and flow coefficients for the reference configurations and compare these with the Boeing configurations which incorporated a longer splitter between the fan and primary flows. A further comparison was made between the JT8D-100 series nozzles and the Boeing JT8D-9/727 production nozzle performance. A statistical analysis was used to compare configurations which showed the performance (velocity coefficient) of the reference and the Boeing configuration was the same for the JT8D-109. It also showed no difference between reference and the Boeing configuration for the JT8D-115 and no difference for the JT8D-117 nozzles. Bypass ratio (match) was shown to be equally dependent on splitter position as on nozzle area within the range investigated. The nozzles were very similar in flow coefficient within an engine family. Excellent profile data was recorded. The effects of swirl on the nozzle performance was examined and found to degrade the velocity and flow coefficients.

Haugan, W. J.↗

NASA NTRS2010

Enhancements to the NASA/Goddard Space Flight Center (GSFC) Space Environment Simulator (SES) Facility to Support Cryogenic Testing of the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM)

NASA is the mission lead for the James Webb Space Telescope (JWST), the next of the "Great Observatories", scheduled for launch in 2014. It is directly responsible for the integration and test of the Integrated Science Instrument Module (ISIM), which includes a composite truss structure provided by NASA, and four science instruments sponsored and provided by NASA, the European Space Agency (ESA), the Canadian Space Agency (CSA), and the European Consortium (EC). Three of the four instruments are passively cooled and designed to operate at temperatures in the 36K to 40K range, and the fourth instrument is actively cooled to approximately 6K. The ISIM will undergo several performance tests at various levels of integration in the NASA Goddard Space Flight Center's (GSFC) Space Environment Simulator (SES), GSFC's largest thermal vacuum chamber. These activities range from Cryo-cycling the bare flight composite structure to thermal balance and performance testing of the full ISIM module. This paper describes the enhancements made to the SES chamber in order to support all cryogenic thermal vacuum testing of the ISIM. Upgrades discussed include: design and fabrication of a very large, removable and reconfigurable helium shroud; a new valve box permitting independent flow control of gaseous helium (GHe) to up to ten zones; and development of in-situ 3-dimensional photogrammetry capability in a cryogenic environment. Also presented will be select results from several facility tests already conducted to verify the chamber capabilities and optimize operational procedures, including the Helium Shroud -03 Configuration Acceptance Test, and the Helium Shroud -01 Configuration Chamber Certification Test.

Cleveland, Paul↗

DOE OSTI2013

Uncertainty of Personnel Dosimetry Systems Using Performance Data Testing

While accreditation programs require a study of uncertainty for each dosimeter model for which accreditation is sought (Torres 2005, DOE 1986), no one method is specifically recommended by accrediting bodies. Typically, the methods used to determine uncertainty have included the partial differentiation method described in the U.S. Guide to Uncertainty in Measurements (ANSI 1997) or the use of Monte Carlo techniques and probability distribution functions to generate simulated dose results. Each of these techniques has particular strengths and should be employed when the areas of uncertainty are required to be understood in detail. However, the uncertainty of dosimeter results can also be determined using a Model II One-Way Analysis of Variance technique and accreditation testing data (Cummings and Flood 2010). The strengths of this method are (1) the method is based in robust and well-accepted statistical techniques; (2) the method is straightforward and easily applied to dose algorithms, which are so complex as to render the use of other methods unwieldy; and (3) the method uses dosimeter performance data obtained during accreditation. The general method and criteria of inclusion of radiation types and fields are discussed.

Cummings, Frederick (Rick) M.↗

DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2011

NASA TEERM Hexavalent Chrome Alternatives Projects

This slide presentation reviews the NASA project to select an alternative to hexavalent chrome in the aerospace industry. Included is a recent historic testing and research that the Agency has performed on (1) the external tank, (2) the shuttle orbiter, (3) the Shuttle Rocket Booster, and (4) the Space Shuttle Main Engine. Other related Technology Evaluation for Environmental Risk Mitigation (TEERM) projects are reviewed. The Phase I process of the project performed testing of alternatives the results are shown in a chart for different coating systems. International collaboration was also reviewed. Phase II involves further testing of pretreatment and primers for 6 and 12 months of exposure to conditions at Launch Pad and the beach. Further test were performed to characterize the life cycle corrosion of the space vehicles. A new task is described as a joint project with the Department of Defense to identify a Hex Chrome Free Coatings for Electronics.

Kessel, Kurt↗

NASA NTRS2003

Integration, Testing and Performance of the Infrared Multi-Object Spectrometer

The Infrared Multi-Object Spectrometer (IRMOS) is a principle investigator-class instrument for the Kitt Peak National Observatory 2.1 m and Mayall 3.8 m telescopes. IRMOS is a near-IR (0.8 - 2.5 micron) spectrometer with low-to mid-resolving power (R = lambda/delta lambda = 300 - 3000). On the 3.8 m telescope, IRMOS produces simultaneous spectra of approximately 100 objects in its approximately 3 x 2 arcmin field of view using a commercial micro electro-mechanical systems (MEMS) digital micro-mirror device (DMD) from Texas Instruments. The multi-mirror array DMD operates as a real-time programmable slit mask. The all-reflective optical design consists of two imaging subsystems. The focal reducer images the focal plane of the telescope onto the DMD field stop, and the spectrograph images the DMD onto a large-format detector. The instrument operates at approximately 80 K, cooled by a single electro-mechanical cryocooler. The bench and all components are made from aluminum 6061-T651. There are three cryogenic mechanisms. We describe laboratory integration and test of IRMOS before shipment to Kitt Peak. We give an overview of the optical alignment technique and integration of optical, mechanical, electrical and cryogenic subsystems. We compare optical test results to model predictions of point spread function size and morphology, contrast, and stray light. We discuss some lessons learned and conclude with a prediction for performance on the telescope.

Ohl, Raymond G.↗

NASA NTRS2011

C-Band Airport Surface Communications System Standards Development. Phase II Final Report. Volume 2: Test Bed Performance Evaluation and Final AeroMACS Recommendations

This report is provided as part of ITT s NASA Glenn Research Center Aerospace Communication Systems Technical Support (ACSTS) contract NNC05CA85C, Task 7: New ATM Requirements-Future Communications, C-Band and L-Band Communications Standard Development and was based on direction provided by FAA project-level agreements for New ATM Requirements-Future Communications. Task 7 included two subtasks. Subtask 7-1 addressed C-band (5091- to 5150-MHz) airport surface data communications standards development, systems engineering, test bed and prototype development, and tests and demonstrations to establish operational capability for the Aeronautical Mobile Airport Communications System (AeroMACS). Subtask 7-2 focused on systems engineering and development support of the L-band digital aeronautical communications system (L-DACS). Subtask 7-1 consisted of two phases. Phase I included development of AeroMACS concepts of use, requirements, architecture, and initial high-level safety risk assessment. Phase II builds on Phase I results and is presented in two volumes. Volume I is devoted to concepts of use, system requirements, and architecture, including AeroMACS design considerations. Volume II (this document) describes an AeroMACS prototype evaluation and presents final AeroMACS recommendations. This report also describes airport categorization and channelization methodologies. The purposes of the airport categorization task were (1) to facilitate initial AeroMACS architecture designs and enable budgetary projections by creating a set of airport categories based on common airport characteristics and design objectives, and (2) to offer high-level guidance to potential AeroMACS technology and policy development sponsors and service providers. A channelization plan methodology was developed because a common global methodology is needed to assure seamless interoperability among diverse AeroMACS services potentially supplied by multiple service providers.

Hall, Edward↗