Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “THERMOCOUPLES”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

AGC-3 Experiment Irradiation Monitoring Data Qualification (Final Report)

The Graphite Technology Development Program will run a series of six experiments to quantify the effects of irradiation on nuclear grade graphite. The third experiment, Advanced Graphite Creep 3 (AGC 3), began with Advanced Test Reactor (ATR) Cycle 152B on November 27, 2012, and ended with ATR Cycle 155B on April 23, 2014. This report documents qualification of AGC 3 experiment irradiation monitoring data for use by the Very High Temperature Reactor (VHTR) Technology Development Office (TDO) Program for research and development activities required to design and license the first VHTR nuclear plant. Qualified data meet the requirements for data collection and use as described in the experiment planning and quality assurance documents. Failed data do not meet the requirements. Trend data may not meet the requirements, but may still provide some useable information. All thermocouples (TCs) functioned throughout the AGC 3 experiment. There was one interval between December 18, 2012, and December 20, 2012, where 10 NULL values were reported for various TCs. These NULL values were deleted from the Nuclear Data Management and Analysis System database. All temperature data are Qualified for use by the VHTR TDO Program. Argon, helium, and total gas flow data were within expected ranges and are Qualified for use by the VHTR TDO Program. Total gas flow was approximately 50 sccm through the AGC 3 experiment capsule. Helium gas flow was briefly increased to 100 sccm during ATR shutdowns. At the start of the AGC 3 experiment, moisture in the outflow gas line was stuck at a constant value of 335.6174 ppmv for the first cycle (Cycle 152B). When the AGC 3 experiment capsule was reinstalled in ATR for Cycle 154B, a new moisture filter was installed. Moisture data from Cycle 152B are Failed. All moisture data from the final three cycles (Cycles 154B, 155A, and 155B) are Qualified for use by the VHTR TDO Program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

AGR-2 Irradiation Test Final As-Run Report, Rev 2

This document presents the as-run analysis of the AGR-2 irradiation experiment. AGR-2 is the second of the planned irradiations for the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program. Funding for this program is provided by the U.S. Department of Energy as part of the Very High Temperature Reactor (VHTR) Technical Development Office (TDO) program. The objectives of the AGR-2 experiment are to: (a) Irradiate UCO (uranium oxycarbide) and UO 2 (uranium dioxide) fuel produced in a large coater. Fuel attributes are based on results obtained from the AGR-1 test and other project activities. (b) Provide irradiated fuel samples for post-irradiation experiment (PIE) and safety testing. (c) Support the development of an understanding of the relationship between fuel fabrication processes, fuel product properties, and irradiation performance. The primary objective of the test was to irradiate both UCO and UO 2 TRISO (tri-structural isotropic) fuel produced from prototypic scale equipment to obtain normal operation and accident condition fuel performance data. The UCO compacts were subjected to a range of burnups and temperatures typical of anticipated prismatic reactor service conditions in three capsules. The test train also includes compacts containing UO 2 particles produced independently by the United States, South Africa, and France in three separate capsules. The range of burnups and temperatures in these capsules were typical of anticipated pebble bed reactor service conditions. The results discussed in this report pertain only to U.S. produced fuel. In order to achieve the test objectives, the AGR-2 experiment was irradiated in the B-12 position of the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) for a total irradiation duration of 559.2 effective full power days (EFPD). Irradiation began on June 22, 2010, and ended on October 16, 2013, spanning 12 ATR power cycles and approximately three and a half calendar years. The test contained six independently controlled and monitored capsules. Each U.S. capsule contained 12 compacts of either UCO or UO2 AGR coated fuel. No fuel particles failed during the AGR-2 irradiation. Final burnup values on a per compact basis ranged from 7.26 to 13.15% FIMA (fissions per initial heavy-metal atom) for UCO fuel, and 9.01 to 10.69% FIMA for UO 2 fuel, while fast fluence values ranged from 1.94 to 3.47 x 10 25 n/m 2 (E >0.18 MeV) for UCO fuel, and from 3.05 to 3.53 x 10 25 n/m 2 (E >0.18 MeV) for UO 2 fuel. Time-average volume-average (TAVA) temperatures on a capsule basis at the end of irradiation ranged from 987°C in Capsule 6 to 1296°C in Capsule 2 for UCO, and from 996 to 1062°C in UO 2 -fueled Capsule 3. By the end of the irradiation, all of the installed thermocouples (TCs) had failed. Fission product release-to-birth (R/B) ratios were quite low. In the UCO capsules, R/B values during the first three cycles were below 10 -6 with the exception of the hotter Capsule 2, in which the R/Bs reached 2 x 10 -6 . In the UO 2 capsule (Capsule 3), the R/B values during the first three cycles were below 10 -7 . R/B values for all following cycles are not reliable due to gas flow and cross talk issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

AGR-2 and AGR-3/4 Release-to-Birth Ratio Data Analysis

A series of Advanced Gas Reactor (AGR) irradiation tests is being conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) in support of development and qualification of tristructural isotropic (TRISO) low enriched fuel used in the High Temperature Gas-cooled Reactor (HTGR). Each AGR test consists of multiple independently controlled and monitored capsules containing fuel compacts placed in a graphite cylinder shrouded by a steel shell. These capsules are instrumented with thermocouples embedded in the graphite enabling temperature control. AGR configuration and irradiation conditions are based on prismatic HTGR technology that is distinguished primarily through use of helium coolant, a low-power-density ceramic core capable of withstanding very high temperatures, and TRISO coated particle fuel. Thus, these tests provide valuable irradiation performance data to support fuel process development, qualify fuel for normal operating conditions, and support development and validation of fuel performance and fission product transport models and codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Data Collection Methods for Validation of Advanced Multi-Resolution Fast Reactor Simulations

In pool-type Sodium Fast Reactors (SFR) the regions most susceptible to thermal striping are the upper instrumentation structure (UIS) and the intermediate heat exchanger (IHX). This project experimentally and computationally (CFD) investigated the thermal mixing in the region exiting the reactor core to the UIS. The thermal mixing phenomenon was simulated using two vertical jets at different velocities and temperatures as prototypic of two adjacent channels out of the core. Thermal jet mixing of anticipated flows at different temperatures and velocities were investigated. Velocity profiles are measured throughout the flow region using Ultrasonic Doppler Velocimetry (UDV), and temperatures along the geometric centerline between the jets were recorded using a thermocouple array. CFD simulations, using COMSOL, were used to initially understand the flow, then to design the experimental apparatus and finally to compare simulation results and measurements characterizing the flows. The experimental results and CFD simulations show that the flow field is characterized into three regions with respective transitions, namely, convective mixing, (flow direction) transitional, and post-mixing. Both experiments and CFD simulations support this observation. For the anticipated SFR conditions the flow is momentum dominated and thus thermal mixing is limited due to the short flow length associated from the exit of the core to the bottom of the UIS. This means that there will be thermal striping at any surface where poorly mixed streams impinge; rather unless lateral mixing is ‘actively promoted out of the core, thermal striping will prevail. Furthermore we note that CFD can be considered a ‘separate effects (computational) test’ and is recommended as part of any integral analysis. To this effect, poorly mixed streams then have potential impact on the rest of the SFR design and scaling, especially placement of internal components, such as the IHX that may see poorly mixed streams. Finally, due to lack or infrastructural support for carrying out sodium experiments, only water experiments and CFD studies were realized in, an otherwise sodium approved facility.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Experimental Investigation of Turbine Vane Heat Transfer for Alternative Fuels

The focus of this program was to experimentally investigate advanced gas turbine cooling schemes and the effects of and factors that contribute to surface deposition from particulate matter found in coal syngas exhaust flows on turbine airfoil heat transfer and film cooling, as well as to characterize surface roughness and determine the effects of surface deposition on turbine components. The program was a comprehensive, multi-disciplinary collaborative effort between aero-thermal and materials faculty researchers and the Department of Energy, National Energy Technology Laboratory (NETL). The primary technical objectives of the program were to evaluate the effects of combustion of syngas fuels on heat transfer to turbine vanes and blades in land-based power generation gas turbine engines. The primary questions to be answered by this investigation were; What are the factors that contribute to particulate deposition on film cooled gas turbine components? An experimental program was performed in a high-temperature and pressure combustion rig at the DOE NETL; What is the effect of coal syngas combustion and surface deposition on turbine airfoil film cooling? Deposition of particulate matter from the combustion gases can block film cooling holes, decreasing the flow of the film coolant and the film cooling effectiveness; How does surface deposition from coal syngas combustion affect turbine surface roughness? Increased surface roughness can increase aerodynamic losses and result in decreased turbine hot section efficiency, increasing engine fuel consumption to maintain desired power output. Convective heat transfer is also greatly affected by the surface roughness of the airfoil surface; Is there any significant effect of surface deposition or erosion on integrity of turbine airfoil thermal barrier coatings (TBC) and do surface deposits react with the TBC in any way to decrease its thermal insulating capability? Spallation and erosion of TBC is a persistent problem in modern turbine engines; and What advancements in film cooling hole geometry and design can increase effectiveness of film cooling in turbines burning high-hydrogen coal syngas due to the higher heat loads and mass flow rates of the core flow? Experimental and numerical investigations of advanced cooling geometries that can improve resistance to surface deposition were performed. The answers to these questions were investigated through experimental measurements of turbine blade surface temperature and coolant coverage (via infrared camera images and thermocouples) and time-varying surface roughness in the NETL high-pressure combustion rig with accelerated, simulated surface deposition and advanced cooling hole concepts, coupled with detailed materials analysis and characterization using conventional methods of Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), X-Ray Diffraction (XRD), 3-D Surface Topography (using a 3-D stylus profilometer). Detailed surface temperatures and cooling effectiveness could not be measured due to issues with the NETL infrared camera system. In collaboration with faculty startup funding from the principal investigator, experimental and numerical investigations were performed of an advanced film cooling hole geometry, the anti-vortex hole (AVH), focusing on improving cooling effectiveness and decreasing the counter-rotating vortex of conventional cooling holes which can entrain mainstream particulate matter to the surface. The potential benefit of this program is in gaining a fundamental understanding of how the use of alternative fuels will effect the operation of modern gas turbine engines, providing valuable data for more effective cooling designs for future turbine systems utilizing alternative fuels.

10 SYNTHETIC FUELS↗
DOE OSTI2015

AGR-3/4 Final Data Qualification Report for ATR Cycles 151A through 155B-1

This report provides the qualification status of experimental data for the entire Advanced Gas Reactor 3/4 (AGR 3/4) fuel irradiation. AGR-3/4 is the third in a series of planned irradiation experiments conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) for the AGR Fuel Development and Qualification Program, which supports development of the advanced reactor technology under the INL ART Technology Development Office (TDO). The main objective of AGR-3/4 irradiation is to provide a known source of fission products for subsequent transport through compact matrix and structural graphite materials due to the presence of designed-to-fail fuel particles. Full power irradiation of the AGR 3/4 test began on December 14, 2011 (ATR Cycle 151A), and was completed on April 12, 2014 (end of ATR Cycle 155B) after 369.1 effective full power days of irradiation. The AGR-3/4 test was in the reactor core for eight of the ten ATR cycles between 151A and 155B. During the unplanned outage cycle, 153A, the experiment was removed from the ATR northeast flux trap (NEFT) location and stored in the ATR canal. This was to prevent overheating of fuel compacts due to higher than normal ATR power during the subsequent Powered Axial Locator Mechanism cycle, 153B. The AGR 3/4 test was inserted back into the ATR NEFT location during the outage of ATR Cycle 154A on April 26, 2013. Therefore, the AGR-3/4 irradiation data received during these 2 cycles (153A and 153B) are irrelevant and their qualification status isnot included in this report. Additionally, during ATR Cycle 152A the ATR core ran at low power for a short enough duration that the irradiation data are not used for physics and thermal calculations. However, the qualification status of irradiation data for this cycle is still covered in this report. As a result, this report includes data from 8 ATR Cycles: 151A, 151B, 152A, 152B, 154A, 154B, 155A, and 155B, as recorded in the Nuclear Data Management and Analysis System (NDMAS). The AGR 3/4 data streams addressed in this report include thermocouple (TC) temperatures, sweep gas data (flow rates, pressure, and moisture content), and Fission Product Monitoring System (FPMS) data (release rates, release to birth rate ratios [R/Bs], and particle failure counts) for each of the twelve capsules in the AGR 3/4 experiment. During Outage Cycle 155A, fourteen flow meters were installed downstream from fourteen FPMS monitors to measure flows from the monitors; qualification status of these data are also included in the report. The final data qualification status for these data streams is determined by a Data Review Committee (DRC) composed of AGR technical leads, Sitewide Quality Assurance (QA), and NDMAS analysts. For ATR Cycles 151A through 154B, the DRC convened on February 12, 2014, reviewed the data acquisition process, and considered whether the data met the requirements for data collection as specified in QA approved INL ART TDO data collection plans. The DRC also examined the results of NDMAS data testing and statistical analyses, and confirmed the qualification status of the data as given in this report. The qualification status of AGR-3/4 irradiation data during the first six cycles were previously reported in INL/EXT-14-31186 document. This report presents data qualification status for the entire AGR-3/4 irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Critical Heat Flux Phenomena at High Pressure & Low Mass Fluxes: NEUP Final Report Part I: Experiments

This report is a preliminary document presenting an overview of the Critical Heat Flux (CHF) phenomenon, the High Pressure Critical Heat Flux facility (HPCHF), preliminary CHF data acquired, and the future direction of the research. The HPCHF facility has been designed and built to study CHF at high pressure and low mass flux ranges in a rod bundle prototypical of conceptual Small Modular Reactor (SMR) designs. The rod bundle is comprised of four electrically heated rods in a 2x2 square rod bundle with a prototypic chopped-cosine axial power profile and equipped with thermocouples at various axial and circumferential positions embedded in each rod for CHF detection. Experimental test parameters for CHF detection range from pressures of ~80 – 160 bar, mass fluxes of ~400 – 1500 kg/m 2 s, and inlet water subcooling from ~30 – 70°C. The preliminary data base established will be further extended in the future along with comparisons to existing CHF correlations, models, etc. whose application ranges may be applicable to the conditions of SMRs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

AGR-2 Irradiated Test Train Preliminary Inspection and Disassembly First Look

The AGR 2 irradiation experiment began in June 2010 and was completed in October 2013. The test train was shipped to the Materials and Fuels Complex in July 2014 for post-irradiation examination (PIE). The first PIE activities included nondestructive examination of the test train, followed by disassembly of the test train and individual capsules and detailed inspection of the capsule contents, including the fuel compacts and their graphite fuel holders. Dimensional metrology was then performed on the compacts, graphite holders, and steel capsule shells. AGR 2 disassembly and metrology were performed with the same equipment used successfully on AGR 1 test train components. Gamma spectrometry of the intact test train gave a preliminary look at the condition of the interior components. No evidence of damage to compacts or graphite components was evident from the isotopic and gross gamma scans. Disassembly of the AGR 2 test train and its capsules was conducted rapidly and efficiently by employing techniques refined during the AGR 1 disassembly campaign. Only one major difficulty was encountered while separating the test train into capsules when thermocouples (of larger diameter than used in AGR 1) and gas lines jammed inside the through tubes of the upper capsules, which required new tooling for extraction. Disassembly of individual capsules was straightforward with only a few minor complications. On the whole, AGR 2 capsule structural components appeared less embrittled than their AGR 1 counterparts. Compacts from AGR 2 Capsules 2, 3, 5, and 6 were in very good condition upon removal. Only relatively minor damage or markings were visible using high resolution photographic inspection. Compact dimensional measurements indicated radial shrinkage between 0.8 to 1.7%, with the greatest shrinkage observed on Capsule 2 compacts that were irradiated at higher temperature. Length shrinkage ranged from 0.1 to 0.9%, with by far the lowest axial shrinkage on Capsule 3 compacts—possibly as a consequence of lower packing fraction or larger particle size. Differences in fast neutron fluence among compacts from these four capsules had no obvious effect on radial and axial shrinkage. (The AGR 2 experiment included Capsule 1 containing French compacts and Capsule 4 with compacts made at Oak Ridge National Laboratory using South African fuel particles. Information on these two batches of AGR 2 fuel compacts is confined to restricted Appendices A and B because of proprietary information limitations.)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Evaluation of Select Heat and Pressure Measurement Gauges for Potential Use in the NRC/OECD High Energy Arc Fault (HEAF) Test Program

In an effort to improve the current state of the art in fire probabilistic risk assessment methodology, the U.S. Nuclear Regulatory Commission, Office of Regulatory Research, contracted Sandia National Laboratories (SNL) to conduct a series of scoping tests to identify thermal and mechanical probes that could be used to characterize the zone of influence (ZOI) during high energy arc fault (HEAF) testing. For the thermal evaluation, passive and active probes were exposed to HEAF-like heat fluxes for a period of 2 seconds at the SNL's National Solar Thermal Test Facility to determine their ability to survive and measure such an extreme environment. Thermal probes tested included temperature lacquers (passive), NANMAC thermocouples, directional flame thermometers, modified plate thermometers, infrared temperature sensors, and a Gardon heat flux gauge. Similarly, passive and active pressure probes were evaluated by exposing them to pressures resulting from various high-explosive detonations at the Sandia Terminal Ballistic Facility. Pressure probes included bikini pressure gauges (passive) and pressure transducers. Results from these tests provided good insight to determine which probes should be considered for use during future HEAF testing.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

In-Situ Acoustic Measurements of Temperature Profile in Extreme Environments

A gasifier’s temperature is the primary characteristic that must be monitored to ensure its performance and the longevity of its refractory. One of the key technological challenges impacting the reliability and economics of coal and biomass gasification is the lack of temperature sensors that are capable of providing accurate, reliable, and long-life performance in an extreme gasification environment. This research has proposed, demonstrated, and validated a novel approach that uses a noninvasive ultrasound method that provides real-time temperature distribution monitoring across the refractory, especially the hot face temperature of the refractory. The essential idea of the ultrasound measurements of segmental temperature distribution is to use an ultrasound propagation waveguide across a refractory that has been engineered to contain multiple internal partial reflectors at known locations. When an ultrasound excitation pulse is introduced on the cold side of the refractory, it will be partially reflected from each scatterer in the US propagation path in the refractory wall and returned to the receiver as a train of partial echoes. The temperature in the corresponding segment can be determined based on recorded ultrasonic waveform and experimentally defined relationship between the speed of sound and temperature. The ultrasound measurement method offers a powerful solution to provide continuous real time temperature monitoring for the occasions that conventional thermal, optical and other sensors are infeasible, such as the impossibility of insertion of temperature sensor, harsh environment, unavailable optical path, and more. Our developed ultrasound system consists of an ultrasound engineered waveguide, ultrasound transducer/receiver, and data acquisition, logging, interpretation, and online display system, which is simple to install on the existing units with minimal modification on the gasifier or use with new units. This system has been successfully tested with a 100 kW pilot scale down flow oxyfuel combustor, capturing in real time temperature changes during all relevant combustion process changes. The ultrasound measurements have excellent agreement with thermo- couple measurements, and appear to be more sensitive to temperature changes before the thermocouples response, which is believed to be the first demonstration of ultrasound measurements segmental temperature distribution across refractories.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

Rayleigh Scattering Combustion Diagnostic

A laser Rayleigh scattering (LRS) temperature diagnostic was developed over 8 weeks with the goal of studying oxy-combustion of pulverized coal char in high temperature reaction environments with high concentrations of carbon dioxide. Algorithms were developed to analyze data collected from the optical diagnostic system and convert the information to temperature measurements. When completed, the diagnostic will allow for the kinetic gasification rates of the oxy-combustion reaction to be obtained, which was previously not possible since the high concentrations of high temperature CO 2 consumed thermocouples that were used to measure flame temperatures inside the flow reactor where the combustion and gasification reactions occur. These kinetic rates are important for studying oxy-combustion processes suitable for application as sustainable energy solutions.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Design and Construction of Experiment for Direct Electron Irradiation of Uranyl Sulfate Solution: Bubble Formation and Thermal Hydraulics Studies

Argonne is assisting SHINE Medical Technologies in developing SHINE, a system for producing fission-product 99 Mo using a D/T-accelerator to produce fission in a non-critical target solution of aqueous uranyl sulfate. We have developed an experimental setup for studying thermal-hydraulics and bubble formation in the uranyl sulfate solution to simulate conditions expected in the SHINE target solution during irradiation. A direct electron beam from the linac accelerator will be used to irradiate a 20 L solution (sector of the solution vessel). Because the solution will undergo radiolytic decomposition, we will be able to study bubble formation and dynamics and effects of convection and temperature on bubble behavior. These experiments will serve as a verification/ validation tool for the thermal-hydraulic model. Utilization of the direct electron beam for irradiation allows homogeneous heating of a large solution volume and simplifies observation of the bubble dynamics simultaneously with thermal-hydraulic data collection, which will complement data collected during operation of the miniSHINE experiment. Irradiation will be conducted using a 30-40 MeV electron beam from the high-power linac accelerator. The total electron-beam power will be 20 kW, which will yield a power density on the order of 1 kW/L. The solution volume will be cooled on the front and back surfaces and central tube to mimic the geometry of the proposed SHINE solution vessel. Also, multiple thermocouples will be inserted into the solution vessel to map thermal profiles. The experimental design is now complete, and installation and testing are in progress.

Chemerisov, Sergey↗
DOE OSTI2015

Experimental Results for Direct Electron Irradiation of a Uranyl Sulfate Solution: Bubble Formation and Thermal Hydraulics Studies

In support of the development of accelerator-driven production of fission product Mo-99 as proposed by SHINE Medical Technologies, a 35 MeV electron linac was used to irradiate depleted-uranium (DU) uranyl sulfate dissolved in pH 1 sulfuric acid at average power densities of 6 kW, 12 kW, and 15 kW. During these irradiations, gas bubbles were generated in the solution due to the radiolytic decomposition of water molecules in the solution. Multiple video cameras were used to record the behavior of bubble generation and transport in the solution. Seven six-channel thermocouples were used to record temperature gradients in the solution from self-heating. Measurements of hydrogen and oxygen concentrations in a helium sweep gas were recorded by a gas chromatograph to estimate production rates during irradiation. These data are being used to validate a computational fluid dynamics (CFD) model of the experiment that includes multiphase flow and a custom bubble injection model for the solution region.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2013

Single-Crystal Sapphire Optical Fiber Sensor Instrumentation

This report summarizes technical progress on the program “Single-Crystal Sapphire Optical Fiber Sensor Instrumentation,” funded by the National Energy Technology Laboratory of the U.S. Department of Energy, and performed by the Center for Photonics Technology of the Bradley Department of Electrical and Computer Engineering at Virginia Tech. This project was completed in three phases, each with a separate focus. Phase I of the program, from October 1999 to April 2002, was devoted to development of sensing schema for use in high temperature, harsh environments. Different sensing designs were proposed and tested in the laboratory. Phase II of the program, from April 2002 to April 2009, focused on bringing the sensor technologies, which had already been successfully demonstrated in the laboratory, to a level where the sensors could be deployed in harsh industrial environments and eventually become commercially viable through a series of field tests. Also, a new sensing scheme was developed and tested with numerous advantages over all previous ones in Phase II. Phase III of the program, September 2009 to December 2013, focused on development of the new sensing scheme for field testing in conjunction with materials engineering of the improved sensor packaging lifetimes. In Phase I, three different sensing principles were studied: sapphire air-gap extrinsic Fabry-Perot sensors; intensity-based polarimetric sensors; and broadband polarimetric sensors. Black body radiation tests and corrosion tests were also performed in this phase. The outcome of the first phase of this program was the selection of broadband polarimetric differential interferometry (BPDI) for further prototype instrumentation development. This approach is based on the measurement of the optical path difference (OPD) between two orthogonally polarized light beams in a single-crystal sapphire disk. At the beginning of Phase II, in June 2004, the BPDI sensor was tested at the Wabash River coal gasifier facility in Terre Haute, Indiana. Due to business conditions at industrial partner and several logistical problems, this field test was not successful. An alternative high-temperature sensing system using sapphire wafer-based extrinsic Fabry-Perot interferometry was then developed as a significant improvement over the BPDI solution. From June 2006 to June 2008, three consecutive field tests were performed with the new sapphire wafer sensors at the TECO coal gasifier in Tampa, Florida. One of the sensors survived in the industrial coal gasifier for 7 months, over which time the existing thermocouples were replaced twice. The outcome of these TECO field tests suggests that the sapphire wafer sensor has very good potential to be commercialized. However packaging and sensor protection issues need additional development. During Phase III, several major improvements in the design and fabrication process of the sensor have been achieved through experiments and theoretical analysis. Studies on the property of the key components in the sensor head, including the sapphire fiber and sapphire wafer, were also conducted, for a better understanding of the sensor behavior. A final design based on all knowledge and experience has been developed, free of any issues encountered during the entire research. Sensors with this design performed well as expected in lab long-term tests, and were deployed in the sensing probe of the final coal-gasifier field test. Sensor packaging and protection was improved through materials engineering through testing of packaging designs in two blank probe packaging tests at Eastman Chemical in Kingsport, TN. Performance analysis of the blank probe packaging resulted in improve package designs culminating in a 3rd generation probe packaging utilized for the full field test of the sapphire optical sensor and materials designed sensor packaging.

47 OTHER INSTRUMENTATION↗
DOE OSTI2016

Silicon Carbide Temperature Monitor Processing Improvements. Status Report

Silicon carbide (SiC) temperature monitors are used as temperature sensors in Advanced Test Reactor (ATR) irradiations at the Idaho National Laboratory (INL). Although thermocouples are typically used to provide real-time temperature indication in instrumented lead tests, other indicators, such as melt wires, are also often included in such tests as an independent technique of detecting peak temperatures incurred during irradiation. In addition, less expensive static capsule tests, which have no leads attached for real-time data transmission, often rely on melt wires as a post-irradiation technique for peak temperature indication. Melt wires are limited in that they can only detect whether a single temperature is or is not exceeded. SiC monitors are advantageous because a single monitor can be used to detect for a range of temperatures that occurred during irradiation. As part of the process initiated to make SiC temperature monitors available at the ATR, post-irradiation evaluations of these monitors have been previously completed at the High Temperature Test Laboratory (HTTL). INL selected the resistance measurement approach for determining irradiation temperature from SiC temperature monitors because it is considered to be the most accurate measurement. The current process involves the repeated annealing of the SiC monitors at incrementally increasing temperature, with resistivity measurements made between annealing steps. The process is time consuming and requires the nearly constant attention of a trained staff member. In addition to the expensive and lengthy post analysis required, the current process adds many potential sources of error in the measurement, as the sensor must be repeatedly moved from furnace to test fixture. This time-consuming post irradiation analysis is a significant portion of the total cost of using these otherwise inexpensive sensors. An additional consideration of this research is that, if the SiC post processing can be automated, it could be performed in an MFC hot cell, further reducing the time and expense of lengthy decontaminations prior to processing. Sections of this report provide a general description of resistivity techniques currently used to infer peak irradiation temperature from silicon carbide temperature monitors along with some representative data, the proposed concepts to improve the process of analyzing irradiated SiC temperature monitors, the completed efforts to prove the proposed concepts, and future activities. The efforts detailed here succeeded in designing and developing a real-time automated SiC resistivity measurement system, and performed two initial test runs. Activities carried out include the assembly and integration of the system hardware; the design and development of a preliminary monitor fixture; the design of a technique to automate the data analysis and processing; the development of the communication, coordination, and user software; and the execution and troubleshooting of test run experiments using the box furnace. Although the automation system performed as required, the designed fixture did not succeed in establishing the needed electrical contacts with the SiC monitor.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2016

Flow and Heat Transfer Tests in New Loop at 2757 kPa (400 psi)

A helium flow and heat transfer experiment has been designed for the new helium flow loop facility at LANL. This new facility is centered on an Aerzen GM 12.4 Root’s blower, selected for operation at higher pressure, up to 2757 kPa, and mass flow rate, up to 400 g/s. This replaces the previous Tuthill PD plus 3206 blower and loop limited to 2067 kPa (300 psi) and 100 g/s. The resistively heated test piece is comprised of 7 electric heaters with embedded thermocouples. The plant design for the Mo100 to Mo99 targets requires sharp bends and geometry changes in the helium flow tube immediately before and after the target. An idealized fully developed flow configuration with straight entry and exit will be tested and compared with an option that employs rectangular tubing to make the bend at a radius consistent with and practical for the actual plant design. The current plant design, with circular tubing and a sudden contraction to rectangular just prior to target entrance, will also be tested. This requires some modification of the test piece, as described in the report.

42 ENGINEERING↗
DOE OSTI2016

AGR-1, AGR-2 and AGR-3/4 Dimensional Change Data Analysis

A series of Advanced Gas Reactor (AGR) experiments have been completed in the Advanced Test Reactor at Idaho National Laboratory in support of qualification and development of tristructural isotropic fuel. Each AGR test consists of multiple independently controlled and monitored capsules containing fuel compacts placed in a graphite cylinder. These capsules are instrumented with thermocouples embedded in the graphite, enabling temperature control. The fuel compacts are composed of fuel particles surrounded by a graphitic A3 matrix material. Dimensional change in AGR fuel compacts is vital because the swelling or shrinkage affects the size of the gas gaps that are used to control temperatures. Analysis of dimensional change in the AGR fuel compacts is needed to establish the variables directly relating to compact shrinkage. The variables initially identified for consideration were matrix density, compact density, fuel packing fraction, uranium loading, fuel particle diameter, cumulative fast neutron fluence, and volume average time average fuel temperature. In addition to the data available from the AGR experiments, the analysis included specimens formed from the same A3 matrix material used in Advanced Graphite Creep (AGC) experiments, which provide graphite creep data during irradiation for design and licensing purposes. The primary purpose of including the AGC specimens was to encompass dimensional behavior at zero packing fraction, zero uranium loading, and zero particle diameter. All possible combinations of first-order variable regressions were considered in the analysis. The study focused on identifying the best regression models for percent change in diameter, length, and volume. Bootstrap analysis was used to ensure the resulting regression models were robust and well-performing. The variables identified as very significant in predicting change in one or more dimensions (diameter, length, and volume) are volume average time average temperature, fast fluence, compact density, packing fraction and fuel particle diameter. Due to the presence of confounding effects between several variables, interpretation of these results is equivocal; the use of multiple statistical tests provides additional confidence in the conclusion.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Modeling and Validation of the Thermal Response of TDI Encapsulating Foam as a function of Initial Density

TDI foams of nominal density from 10 to 45 pound per cubic foot were decomposed within a heated stainless steel container. The pressure in the container and temperatures measured by thermocouples were recorded with each test proceeding to an allowed maximum pressure before venting. Two replicate tests for each of four densities and two orientations in gravity produced very consistent pressure histories. Some thermal responses demonstrate random sudden temperature increases due to decomposition product movement. The pressurization of the container due to the generation of gaseous products is more rapid for denser foams. When heating in the inverted orientation, where gravity is in the opposite direction of the applied heat flux, the liquefied decomposition products move towards the heated plate and the pressure rises more rapidly than in the upright configuration. This effect is present at all the densities tested but becomes more pronounced as density of the foam is decreased. A thermochemical material model implemented in a transient conduction model solved with the finite element method was compared to the test data. The expected uncertainty of the model was estimated using the mean value method and importance factors for the uncertain parameters were estimated. The model that was assessed does not consider the effect of liquefaction or movement of gases. The result of the comparison is that the model uncertainty estimates do not account for the variation in orientation (no gravitational affects are in the model) and therefore the pressure predictions are not distinguishable due to orientation. Temperature predictions were generally in good agreement with the experimental data. Predictions for response locations on the outside of the can benefit from reliable estimates associated with conduction in the metal. For the lighter foams, temperatures measured on the embedded component fall well with the estimated uncertainty intervals indicating the energy transport rate through the decomposed region appears to be accurately estimated. The denser foam tests were terminated at maximum allowed pressure earlier resulting in only small responses at the component. For all densities the following statements are valid: The temperature response of the embedded component in the container depends on the effective conductivity of the foam which attempts to model energy transport through the decomposed foam and on the stainless steel specific heat. The pressure response depends on the activation energy of the reactions and the density of the foam and the foam specific heat and effective conductivity. The temperature responses of other container locations depend heavily on the boundary conditions and the stainless steel conductivity and specific heat.

36 MATERIALS SCIENCE↗