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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.

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DOE OSTI2020

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

The aging of nuclear power plant electrical cables has been the subject of substantial research and development (R&D) projects in the nuclear industry, national and international laboratories, universities, and vendor organizations for several years. More specifically, these R&D efforts were conducted to develop equipment and techniques for assessing age-related degradation of in-service cables in nuclear facilities including power plants, research reactors, waste facilities and fuel fabrication plants. In recent years, cable R&D efforts in the nuclear arena have also included work to develop new cables for the next generation of reactors. Over time, exposure to harsh environmental conditions such as elevated temperatures, radiation, and humidity in nuclear installations can result in age-related degradation and failure of cables. In the current fleet of nuclear reactors, there are thousands of miles of cabling installed in each plant and many of these cables are exposed to these harsh environmental conditions. For these cables, the jacket and insulation polymers harden and become brittle over time, making them more susceptible to crack formation and growth, moisture intrusion, and other mechanisms that can lead to cable failure. Moreover, the existing U.S. fleet of 98 nuclear reactors has an average operating age of 38 years. Many of these nuclear power plants have applied for and almost all have been granted regulatory approval for license renewals to operate for 60 years, 20 years beyond their original 40-year life. Further, subsequent license renewals (SLRs) are underway with a few commercial nuclear power sites already approved to operate up to 80 years. As these reactors pursue operating life extensions, utilities must find a way to address issues associated with age-related degradation of cables. Designers of small modular reactors are also in need of technologies to evaluate the performance of cables that will be installed in harsher environments (e.g. higher temperatures, radiation doses, dose rates, etc.) than those present in current-generation reactors. Today, a variety of cable condition monitoring (CM) techniques have been developed and successfully used in nuclear facilities. These techniques are used to identify age-related degradation and assess the condition of cables to determine if their performance characteristics have changed with age. However, objective criteria must be developed for these CM tests to help quantify cable condition and thereby develop repair and replacement schedules. With operating life extending to 80 years and more SLRs on the horizon, both nuclear facilities and regulators need an objective means to determine the aged condition of cables.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

36 MATERIALS SCIENCE↗

NASA NTRS1977

Rigid cable support for blind installations

Mechanical support structure, originally designed for use with electrical cables, can support hydraulic, pneumatic, and cryogenic lines where bends are required, assemblies are inaccessible, and conduits are impractical. Support is also light in weight and offers means of damping vibration.

Abbott, J. R.↗

NASA NTRS2010

SSME Electrical Harness and Cable Development and Evolution

The Space Shuttle Main Engine (SSME) electrical harness and cable system consists of the various interconnecting devices necessary for operation of complex rocket engine functions. Thirty seven harnesses incorporate unique connectors, backshell adapters, conductors, insulation, shielding, and physical barriers for a long maintenance-free life while providing the means to satisfy performance requirements and to mitigate adverse environmental influences. The objective of this paper is to provide a description of the SSME electrical harness and cable designs as well as the development history and lessons learned.

Abrams, Russ↗

NASA NTRS1998

Electrical signal transmission in a bone cell network: the influence of a discrete gap junction

A refined electrical cable model is formulated to investigate the role of a discrete gap junction in the intracellular transmission of electrical signals in an electrically coupled system of osteocytes and osteoblasts in an osteon. The model also examines the influence of the ratio q between the membrane's electrical time constant and the characteristic time of pore fluid pressure, the circular, cylindrical geometry of the osteon, and key simplifying assumptions in our earlier continuous cable model (see Zhang, D., S. C. Cowin, and S. Weinbaum. Electrical signal transmission and gap junction regulation in a bone cell network: A cable model for an osteon. Ann. Biomed. Eng. 25:379-396, 1997). Using this refined model, it is shown that (1) the intracellular potential amplitude at the osteoblastic end of the osteonal cable retains the character of a combination of a low-pass and a high-pass filter as the corner frequency varies in the physiological range; (2) the presence of a discrete gap junction near a resting osteoblast can lead to significant modulation of the intracellular potential and current in the osteoblast for measured values of the gap junction coupling strength; and (3) the circular, cylindrical geometry of the osteon is well simulated by the beam analogy used in Zhang et al.

Non-NASA Center↗

NASA NTRS1987

Tester for Multiple-Conductor Cables

Portable testing circuit enables technician to determine quickly wiring errors in multiple-conductor electrical cable or terminal connectors. Active unit tester made of inexpensive integrated circuits and other readily available components. Timer and one-shot generate pulses counted by shift registers. Shift-register output terminals wired to connector pins so voltage applied to each pin in sequence.

Wirth, Manfred N.↗

DOE OSTI2022

Dose Rate Effects in the Aging of Nuclear Cable Insulation Subjected to Gamma Radiation

In nuclear power plants (NPPs), the aging of polymer-based electrical cable insulation must be effectively monitored to ensure the safe and reliable operation of NPPs. Gamma radiation is one of the main environmental stressors causing degradation of cable insulation. For a given total dose of absorbed gamma radiation, damage due to gamma irradiation may be dose rate dependent. The purpose of this work is to confirm whether a dose rate effect exists for the cable insulation made by crosslinked polyethylene (XLPE) and ethylene propylene rubber (EPR), quantify the relationship between degradation rate and dose rate, and explore the correlation of different measured properties. The dose rate effects at 1800 Gy/h, 200 Gy/h, and 100 Gy/h using 60Co gamma irradiation on cable aging was studied. Different types of cable insulation, including two XLPEs and one EPR, were irradiated at the different dose rates with a total dose around 300 kGy at 26 °C. The properties of unirradiated and irradiated samples were characterized by mass change, yellowness index, and other ongoing measurements. Dose rate effects were observed for mass change data of XLPE and EPR.

Li, Donghui↗

NASA NTRS1992

Modified Spot Welder Solders Flat Cables

Soldering device, essentially modified spot welder, melts high-melting-temperature solders without damaging plastic insulation on flat electrical cables. Solder preform rests on exposed conductor of cable, under connector pin. Electrodes press pin/preform/conductor sandwich together and supply pulse of current to melt preform, bonding pin to conductor. Anvil acts as support and heat sink. Device used to solder flexible ribbon cables to subminiature pin connectors.

Haehner, Carl L.↗

NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge Chamber

NASAs Evolutionary Xenon Thruster (NEXT) Long-Duration Test (LDT) is part of the comprehensive service life assessment of the NEXT thruster. The test was voluntarily terminated in April 2014 after accumulating 51,184 hours of high voltage operation, processing 918 kg of xenon, and delivering 35.5 MN-s of total impulse. This presentation covers the post-test inspection of the thruster hardware, in particular of the discharge chamber and other miscellaneous components such as propellant isolators and electrical cabling.

Ion Thrusters↗

NASA NTRS1982

Explosive Separation of Electrical Connectors

Concept proposed for separating electrical cable that connects the Space Shuttle to deployable payloads could be used to sever electrical connections in other inaccessible environments. Although triggered explosively, connector would not release combustion products that could damage sensitive electronics. Suggested applications are undersea exploration, chemical processing and areas with high levels of radiation.

Barbour, R. T.↗

NASA NTRS1987

Tangleproof Coupling

Along with Marshall Space Flight Center, Phase 2 Automation developed a unique rotary coupling capable of connecting a large number of electrical cables to a turntable without stressing the cables or tangling them. Device accommodates 246 cables and allows the turntable to rotate through an arc of 320 degrees. At extremes of rotation the cables remain loose enough so that they are not pulled taut and overstressed; a halfway rotation, the cables are not so loose that they tangle. The rotary connector was developed to carry electrical signals to and from a telescope platform on the satellite without employing a complex set of slip rings which are electrically noisy and could have caused signal interference.

Source record↗

DOE OSTI2021

Monitoring Degradation of Nuclear Cable Insulation Subjected To Sequential and Simultaneous Thermal and Radiation Aging

Predicting useful remaining life of cables in nuclear power plants is a topic of growing interest as plant continue to age. A typical electrical cable consists of polymeric materials, such as the cable jacket and insulation, which are susceptible to degradation due to exposure to both elevated temperatures and gamma irradiation over decades of service. In this work two insulation materials, crosslinked polyethylene (XLPE) and ethylene propylene diene (EPDM) elastomer, were characterized to quantify aging using total color difference and indenter modulus. Since the effects of thermal and gamma radiation are not additive but coupled, the effects of different aging scenarios including sequential and simultaneous aging were also evaluated. In the case of sequential aging, two aging scenarios were explored where the order in which thermal and gamma radiation received were altered. Total color difference of XLPE showed that sequentially aged insulation specimens, which received radiation first, degraded slightly more at maximum exposure than specimens which received thermal first. Similarly, in the case of EPDM, the extent of degradation evaluated using total color difference was found to be most severe in the case of sequentially aged insulation specimens which received radiation first. Indenter modulus was found to be insensitive to aging for XLPE but trended for EPDM. The largest variations were observed for the sequentially aged insulation specimens which received radiation first, similar to what was observed for total color difference.

Pallaka, Madhusudhan Reddy↗

DOE OSTI2025

Design and performance validation of a high-temperature downhole permanent magnet generator used for an electro-pulse boring system in geothermal energy applications

Novel, direct-energy drilling technologies such as electro-pulse boring, have the potential to significantly increase the speed and depth of geothermal drilling but have not achieved widespread adoption due to several economic and technical barriers. One major challenge is that these drilling systems require electric power downhole. The current practice is to supply power to the drill string components by running electric cables down the geothermal well, but at the targeted well depths, this practice is cost-inhibitive, inefficient in terms of power consumption, and adds an additional failure point with the long cabling going through a highly corrosive, high-temperature environment. A solution to this problem is to develop high-temperature electric generator technology that can generate the required power downhole. Such a generator must also operate with high efficiency at the target downhole ambient temperature of 250 °C. In this paper, we investigate the various design considerations for this concept and subsequently design the downhole electric generator using a multi-objective design optimization approach. Through electromagnetic-, thermal- and short-circuit fault condition analysis, it is demonstrated that the optimized downhole electric generator concept presented in this paper can meet the performance requirements within this extreme drilling environment. Most remarkably, it is shown that a generator efficiency of 90% is achieved. In conclusion, to validate the results presented in this paper, a prototype generator is built and its performance is measured at 250 °C using a test bench uniquely developed for this application.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Non-Conductor-Contact Surface Wave Reflectometry for Cable Insulation Damage Detection

Here, this paper presents a non-conductor-contact surface wave-based reflectometry technique to detect and locate missing or damaged insulation and/or jacket of electrical cables. The described sensor may be uniquely and practically implemented on live cables as a non-destructive evaluation (NDE) method since it may be applied to the outer insulation/jacket of a cable and requires no direct contact to the conductor. The innovation lies in a high-frequency surface wave launcher that can introduce broadband signals in the GHz frequencies that insure maximum electromagnetic (EM) energy localization within the insulation and/or jacket material. By further processing the reflection data in the frequency domain, the location and severity of insulation damage is detected. Simulated results of thin, thick, short, and long cables show the results expected from small, medium, and large damage regions. For example, the detection of 40 mm-long damage region at 40 m distance on a 50 m long cable (2.44 cm diameter) is demonstrated. Experimental results are presented that validate simulation findings.

Non Destructive Evaluation↗

DOE OSTI2023

Signal Processing of Multiplexed Optical PWM Signals for Sensor Arrays in Nuclear Environments

Safe and effective generation of terrestrial nuclear power greatly benefits from the actionable data provided by the array of sensors located throughout a plant to provide a holistic online indication of reactor operation. This array includes sensors for monitoring coolant flow and pressure, temperature and heat transfer, radiation levels, structure health monitoring, and other critical parameters for reactor operation. While sensors capable of measuring these parameters have been developed, the electronics used in the pre-amplification and analog-to-digital conversion of the small signals they produce are extremely sensitive and susceptible to damage by high-temperatures and radiation environments nuclear reactors encounter while generating power. The small signals from sensors in nuclear power plants (NPPs) are transmitted over long cable runs which introduce dispersion artifacts into the signals of interest as well as electromagnetic interference (EMI) from lighting fixtures, pumps, mains electricity, and other equipment. To overcome these challenges, a front-end digitization (FREND) platform has been developed to use radiation-tolerant electronics to multiplex, amplify, and optically encode signals from an array of sensors for transmission over an optical fiber to mitigate dispersion and EMI artifacts from long runs of electrical cabling. To recover the optically transmitted data, a signal processing scheme based on 1-dimensional template matching to an indexing channel is described herein and demonstrated to have an effective bit-depth of 9.2 bits (1%). This scheme has been validated in proof-of-concept, non-nuclear testing and preliminary experimental results show good agreement between the measured optical output and and sensor input signals. The FREND system represents a low-loss data link between sensors in nuclear environments and data acquisition hardware which is aimed at improving the signal-to-noise ratio of the data acquired from these sensors to provide better information to operators and researchers.

Sweeney, Dan↗

DOE OSTI2023

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

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

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Nondestructive Evaluation (NDE) of Cable Anomalies using Frequency Domain Reflectometry (FDR) and Spread Spectrum Time Domain Reflectometry (SSTDR)

This report presents a comparative assessment of the performance of frequency domain reflectometry (FDR) and spread spectrum time domain reflectometry (SSTDR) in detecting a wide range of electrical cable anomalies. All tests and results reported herein were performed at the PNNL Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable and motor test bed. The primary objective of this work was to evaluate the effectiveness of SSTDR, a fledgling cable monitoring technique that shows promise for application in online monitoring of energized cable systems, against FDR, an offline technique widely employed in the nuclear power plant (NPP) industry. FDR tests are becoming more widely used in nuclear power plant cable aging management and test programs – particularly for low voltage cables. FDR capabilities for these kinds of tests have been reported by PNNL and others. The FDR test is performed on de-energized cables by connecting the FDR instrument to two of the cable conductors, or one conductor and the shield. A broad band low voltage (< 5 V) chirp is introduced in the cable, and any reflected response is captured in the frequency domain. The captured reflection is then processed by performing an inverse Fourier transform to a time domain response which can then be converted to a distance response based on the cable velocity of propagation (VoP). SSTDR measurements are functionally similar to FDR measurements in that a broad-band voltage signal composed of a square or sine wave modulated pseudo-random sequence of chips (< 5 volts), is injected onto one of the cable conductors. The injected signal will experience partial energy reflection and transmission at each impedance discontinuity along the transmission line. Any reflected response is detected by computing a cross-correlation between the reflected signals and a delayed copy of the incident SSTDR signal. the time delay for the reflected signal to experience the best matched correlation with the incident signal, indicates the travel time for the signal to reach a change in impedance. By knowing this time delay and velocity of propagation (VoP) of the signal, one can compute the physical distance. A big advantage that SSTDR measurements have over other methods is the ability to be connected to energized or live wires (currently up to 1kV) thereby enabling online monitoring of cables. SSTDR has been used successfully in several applications, e.g., aircraft, rail, and photovoltaic systems. In this work FDR and SSTDR cable assessment techniques were used to characterize a variety of cable anomalies and faults including: (1) Presence or absence of a motor; (2) Ground faults and short circuit faults; (3) Moist environments and water ingress faults; (4) Accelerated thermal aging. Both shielded and non-shielded cables were evaluated in this report. Offline measurements were made using FDR and online measurements were made by SSTDR for a range of test scenarios. Based on the results across all cable anomalies evaluated in this study, FDR displayed high sensitivity towards cable condition assessment, while SSTDR showed promise for future application in monitoring NPP cable systems. However, further developments are suggested to improve the resolution and sensitivity of SSTDR towards faults and anomalies in low voltage cables.rt presents a comparative

42 ENGINEERING↗

DOE OSTI2022

Summary Report of HERO WEC Test Article for Waves to Water: Electrical Power Take-Off

The National Renewable Energy Laboratory (NREL) designed and fabricated the hydraulic and electric reverse osmosis (HERO) wave energy converter (WEC), which is a modular system that can utilize either an electrical or hydraulic power take-off (PTO) system to power a desalination device. The method by which this device can convert mechanical work to either hydraulic or electrical energy is by harnessing the energy from waves via a rotary output shaft. This report describes the electrical configuration, where a rotary generator replaces the pump in the hydraulic configuration to power a submersible pump and reverse osmosis unit via an electrical cable, rather than a hydraulic line/hose. This device is of a non-proprietary design where every aspect of the design is made public, including the physical designs, non-proprietary cost data, and electrical drawings developed for the build of this device.

16 TIDAL AND WAVE POWER↗