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At least 919 records · Page 51

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Hermetic edge-connect headers and corresponding connectors

A hermetically-sealed edge-connect header that can withstand high temperatures, high pressures (or high vacuum levels), and high vibration environments, along with two corresponding connectors are disclosed. After brazing the edge-connect header components, the assembly is machined to form a slot with a portion of each of a plurality of electrical conductors removed in the machining process, resulting in a header with a high pin density. During the process of mating the first connector design to the edge-connect header, a plurality of wipers in the connector deflect, thereby causing the wipers to extend from the connector and contact the corresponding electrical conductors in the header. During the process of mating the second connector design to the edge-connect header, each of a plurality of wipers formed of low-mass, compliant metal wool, forms multiple contact points with a corresponding electrical conductor in the header.

Kellogg, Rick A.↗

DOE OSTI2022

Hermetic edge-connect headers and corresponding connectors

Kellogg, Rick A.↗

NASA NTRS1991

A bulk flow model of a brush seal system

Fibers can be readily fabricated into a variety of seal configurations that are compliant and responsive to high speed or lightly loaded systems. A linear, circular, or contoured brush seal system is a contact seal consisting of the bristle pattern and hardened interface. When compared to a labyrinth seal, the brush seal system is superior and features low leakage, dynamic stability, and permits compliant structures. But in turn, the system usually requires a hardened smooth interface and permits only limited pressure drops. Wear life and wear debris for operations with static or dynamic excitation are largely undetermined. A seal system involves control of fluid within specific boundaries. The brush and rub ring (or rub surface) form a seal system. Design similitudes, a bulk flow model, and rub ring (interface) coatings are discussed. The bulk flow model calculations are based on flows in porous media and filters. The coatings work is based on experience and expanded to include current practice.

Hendricks, R. C.↗

NASA NTRS1988

Three-in-one gage

The Three-in-One Gage is a three way gage designed to measure pressure, temperature, and displacement at the same port continuously. The Two-in-One Gage is a two way gage designed to measure pressure and temperature in the same port continuously. The Two-in-One is an adaptation of the Three-in-One to incorporate dual seals, however, without the proximity sensor. The Three-in-One is assembled using two Type K thermocouples, 1 Kulite Pressure Transducer, and one Kaman Proximity Displacement Sensor. Tests of performance were completed.

Garecht, D. M.↗

DOE OSTI2023

NREL 25-cm2 High-Pressure Low-Temperature Electrolysis Cell Hardware (Open Source)

This data resource describes an open-source cell hardware that enables low temperature electrolysis (LTE) testing at elevated pressures. Existing commercial options have several downsides when it comes to R&D testing. They are often not designed for repeated reassembly, may not be able to accommodate porous transport layers with different thicknesses, and do not give state-of-the-art performance. Therefore, this hardware was developed specifically with LTE R&D in mind and its design is being made available to the global LTE community. This work was planned and funded by the U.S. Department of Energy's H2NEW consortium (https://h2new.energy.gov/). The hardware design package (.zip file) details the drawings, auxiliary materials, and procedures required to fabricate, assemble, and operate the National Renewable Energy Laboratory's (NREL's) high-pressure low-temperature electrolysis cells. While the hardware itself—end plates, current collectors, flow fields, bolts and washers, tube fittings—is always the same, the assembly and operating procedures may change depending on the active materials being tested, especially for the membrane. Material-specific assembly and operating procedures will be posted to the H2NEW website as they are developed and validated. Disclaimer: The documents and drawings included in this download package describe a design for a low temperature electrolysis hardware that is intended to comply with leak testing according to ASME B31.1. Safe operation at ambient and elevated pressures is the sole responsibility of the end user, which should be evaluated on a case-by-case basis for each individual cell. Factors affecting the sealing capability may depend on, for example, machining quality, cell assembly components, operating conditions, and operating history. Operation at pressure should only be performed on qualified test stands by qualified operators. NREL/ALLIANCE FOR SUSTAINABLE ENERGY, LLC/DOE DISCLAIM ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND MAKES NO WARRANTY AS TO THE ACCURACY, COMPLETENESS, OR USEFULNESS OF ANY INFORMATION PROVIDED HEREIN. USE OF THIS PACKAGE IS AT THE USER’S OWN RISK.

08 HYDROGEN↗

NASA NTRS1998

Simultaneous in situ Optical Monitoring Techniques during Crystal Growth of ZnSe by Physical Vapor Transport

ZnSe crystals grown in sealed ampoules by the physical vapor transport method were monitored in situ using three techniques, simultaneously. A Michelson interferometer was set-up to observe the growth rate and surface morphological evolution. An interference pattern (interferogram) is formed by the interaction between the reflection of a HeNe laser (632.8 nm wavelength) off the crystal-vapor interface and a reference beam from the same laser. Preliminary results indicate that the rate of growth/thermal-etching can be calculated using analog data acquisition and simple fringe counting techniques. Gross surface features may also be observed using a digital frame grabber and fringe analysis software. The second in situ technique uses optical absorption to determine the partial pressures of the vapor species. The Se2 and Zn vapor species present in the sealed ampoule absorb light at characteristic wavelengths. The optical absorption is determined by monitoring the light intensity difference between the sample and reference beams. The Se2 Partial pressure profile along the length of the ampoule was estimated from the vibronic absorption peaks at 340.5, 350.8, 361.3 and 379.2 nm using the Beer's law constants established in the calibration runs of pure Se. Finally, because the high temperature crystal growth furnace contains windows, in situ visual observation of the growing crystal is also possible. The use of these techniques not only permits in situ investigation of high temperature vapor growth of semiconductors, but also offers the potential for real time feed back on the growing crystal and allows the possibility of actively controlling the growth process.

Su, C.- H.↗

DOE OSTI2020

Aerosol Envelope Sealing of New Residences

This project investigated the use of an aerosol-based sealing method to reduce air leakage of new homes in the United States. The process involves pressurizing the building while dispersing an aerosol sealant “fog” to the building interior. As air escapes the building through leaks in the envelope, the sealant particles are carried to the leaks where they make contact and stick, sealing the leaks. A standard blower door is used to facilitate the sealing process and to provide real-time feedback and a permanent record of the sealing. The technology is thus capable of simultaneously measuring, locating, and sealing leaks in a building automatically.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Aerosol Envelope Sealing of New Residences

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Fuel Properties of Oxymethylene Ethers with Terminating Groups from Methyl to Butyl

Oxymethylene ethers (OMEs) have been studied as possible additives or replacements for diesel fuels. Typically, studies have considered only methyl-terminated OMEs. Recent structure-property relationship models suggest that extended-alkyl OMEs may provide improvements to many of the properties of methyl-terminated OMEs that make them less suitable as diesel fuel blendstocks. In this work, we describe the synthesis and characterization of 16 different OMEs with methyl, ethyl, propyl, butyl, isopropyl, and isobutyl terminating alkyl groups with varying oxymethylene chain length. Indicated Cetane Number, Lower Heating Value, Flash Point, Density, Viscosity, Vapor Pressure, and Oxidative Stability are tested via ASTM standard methods. Additionally, Water Solubility, Boiling Point, seal material compatibility, and sooting propensity (via the Yield Sooting Index) are measured for these fuels. For diesel compatibility, all tested OMEs except smaller methyl and ethyl OMEs, and the branched isopropyl OME, meet cetane number requirements. Further, extending the alkyl end group increases the heating value, but all OMEs, due to their oxygen content, have heating values less than diesel; despite this, all OMEs show significant reductions in soot production per unit heating value. Only the heaviest OMEs meet diesel viscosity requirements, and most are higher density than diesel. OMEs with larger alkyl groups show the highest stability under accelerated auto-oxidation conditions. Increases in alkyl group length cause order of magnitude reduction in water solubility, from hundreds of g/L for methyl terminated OMEs to hundreds of mg/L for butyl terminated OMEs. Limited seal material testing indicates that PEEK polymers are unaffected by OMEs; while extended alkyl groups may improve compatibility with FKM (Viton), other common elastomers (NBR, silicone) remain incompatible with all tested OMEs. Overall, it is found that methyl-terminated OMEs exhibit the most potential for soot reduction, but OMEs with larger propyl and butyl terminating alkyl groups show improved compatibility with existing diesel systems.

09 BIOMASS FUELS↗

DOE OSTI2024

Managing Subsurface Pressure Buildup and Interference in Commercial-Scale CO 2 Storage Project with Proximal Injection Wells

Large-scale decarbonization using carbon capture and storage (CCS) is likely to involve many commercial-scale CO 2 storage projects located in close proximity to each other. This close proximity raises concerns over pressure interference among the storage projects. Pressure interference between injection and storage efforts can reduce the practicable CO 2 storage resource and force wells to inject CO 2 at a lower rate to avoid the fracture pressure thresholds per United States Environmental Protection Agency (EPA) Class VI well regulations to preserve injection and confining zone integrity and potentially mitigate against inducing seismic activity. These analyses employ numerical full-physics reservoir modeling to evaluate how pressure buildup fronts and CO 2 plumes evolve under commercial-scale injection volumes of CO 2 in which multiple storage sites located in close proximity occur in tandem. The simulation models mimic injection at pseudo basin-scale and assume homogeneous saline formation(s) as storage targets with a pair of upper and lower homogeneous seal layer/s. These analyses specifically investigate the efficacy of two basin-wide reservoir pressure management strategies in addressing the technical challenges associated with pressure buildup and CO 2 plume commingling. The strategies explored include: 1) enlarging the area of injection well spacing (WS) and 2) storing CO 2 in a stacked sequence (SSS) of saline formations compared to a single formation. The storage and confining zones properties assumed were held common across the scenarios, unless specified otherwise. Analyses results show that after injecting 4 million tons per year for 30 years using 4 separate wells (each injecting 1 million metric tons per year), the radius of CO 2 plume extends to a mere 3 km or less from injection wells. Meanwhile, the radius of pressure buildup ranges on the order of tens to a few hundreds of kilometers, depending on the magnitude of pressure buildup threshold that one would use to define the front. CO 2 plume commingling from different injection wells appears to occur 50 years post-injection, especially under scenarios with narrowly spaced (i.e., < 5 km apart) injection well locations. Findings from sensitivity cases on the well spacing suggest that storage formations modeled would require different well spacing to avoid fracture pressure thresholds. For instance, modeled storage formations with high fracture gradients (i.e., 0.8 psi/ft) would need less than 5–km well spacing, whereas those with lower fracture gradients (i.e., 0.7 psi/ft) would need approximately 20–km well spacing, based on assumed modeling parameters. Under stacked injection, the pressure challenges (described above) still exist but are more alleviated due to distributing the same injection volume across more available reservoir volume. These analyses demonstrate that stacked-sequence storage can effectively address the challenges, while still providing the same target CO 2 storage volumes and allowing a large number of storage projects to be deployed in the same basin by better utilizing the available storage resource across different reservoir depths. Among cases modeled, the resulting pressure buildup front is most suppressed when each storage project distributes injection volumes over several wells, each of which injects a portion of the total CO 2 across the stacked sequence. This strategy results in the smallest CO 2 aerial footprint amongst scenarios evaluated but also shows the largest reduction in the pressure buildup at the top of perforation at the injection wells (upwards of approximately 42 percent compared to the commercial-scale single-formation storage), the result of which is crucial to maintain caprock integrity. The findings presented by this research draw attention to the importance of greater coordination among storage operators and regulatory stakeholders to foster the upscaling and deployment of CCS. These analyses provide insights into required decision-making when considering multi-project deployment in a shared basin. Because these analyses evaluate a very specific geologic situation, they bear further investigations across other geologic situations.

42 ENGINEERING↗

NASA NTRS1972

Miniature high pressure regulator

Metal bellows, capable of suppling required spring rate and operational stability, replaced diaphragms, sliding seals, and springs in design of small gas regulator.

Wright, H. W., Jr.↗

NASA NTRS1997

Effects of Compression, Staging, and Braid Angle on Braided Rope Seal Performance

Future turbine engines and industrial systems will be operating at increased temperatures to achieve more demanding efficiency and performance goals. In the highest temperature sections of the engine new material systems such as ceramics and intermetallics are being considered to withstand the harsh thermal environment. Components constructed of these low expansion-rate materials experience thermal strains and a resulting reduction of life when rigidly attached to high expansion-rate, superalloy support structures. Seals are being designed to both seal and to serve as compliant mounts allowing for relative thermal growths between high temperature but brittle primary structures and the surrounding support structures. Previous seal research yielded several braided rope seal designs which demonstrated the ability to both seal and serve as a compliant mount. The hybrid seal was constructed of an all-ceramic (alumina-silica) core overbraided with a superalloy wire sheath (cobalt based superalloy). The all ceramic seal was constructed of an all-ceramic (alumina-silica) core overbraided with multiple ceramic (alumina-silica) sheath layers. Program goals for braided rope seals are to improve flow resistance and/or seal resilience. To that end, the current report studies the test results of: baseline and modified hybrid seals; two stage hybrid and two stage all-ceramic seal configurations; and single stage hybrid and single stage all-ceramic seal configurations for a range of seal crush conditions. Hybrid seal modifications include increasing the sheath braid angle and core coverage. For the same percent seal cross-sectional crush, results show that increasing the hybrid seal braid angle increased seal stiffness and seal unit load, resulting in flows approximately one third of the baseline hybrid seal flows. For both hybrid and all-ceramic seals, two stage seal configurations significantly outperformed single stage configurations. Two stage seal flows were at least 30% less than the single stage seal flows for the same seal crush. Furthermore, test results of single stage seals indicate that for both all-ceramic and hybrid seals, a specific seal crush condition exists at which minimum flows are achieved (i.e. increasing seal crush beyond a certain point does not result in better flow performance). Flow results are presented for a range of pressures and temperatures from ambient to 1300 F, before and after scrubbing. Compression tests results show that for both all-ceramic and hybrid seals, seal preload and stiffness increase with seal crush, but residual seal interference remains constant.

Steinetz, Bruce M.↗

NASA NTRS2022

On the Stability and Phase Behavior of Titan's Subsurface Liquid Columns

On Titan, liquid hydrocarbon may stay in the subsurface porous permeable crust known as the alkanofer, analogous to water in Earth’s aquifer. In addition to pressure gradient, the subsurface liquid in alkanofers is subject to vertical compositional grading due to the gravity and temperature gradient. The common wisdom is that the liquid would normally stay underground in a stability established by the pressure that increases with depth as observed in aquifers on Earth. However, Titan’s liquids consist of nitrogen and hydrocarbons, mainly methane and ethane, the behavior of which is very sensitive to temperature and pressure. Consequently, the liquid density does not always increase with depth, thus may introduce a reverse density profile that leads to vertical convective instability of the liquid column. If reverse density profiles are present, capillary pressures arising from liquid trapped within small pores in the crust can help with the column stability. The liquid held in the capillaries can seal the space below it thus helping with the stability, unless the overpressure built from underneath becomes larger than the capillary pressure, which causes leakage to allow the liquids to seep upward from the deep. This situation is analogous to hydrocarbon seeps on Earth, where oil and natural gas escape the reservoir and flow slowly through network of cracks to the surface. An algorithm based on an extended Gibbs equation commonly used in petroleum reservoir engineering is employed in this work to produce pressure, density, and compositional profiles for evaluating the stability and phase behavior of Titan’s subsurface fluids.

Sugata Tan↗

NASA NTRS2012

Suitport Feasibility: Development and Test of a Suitport and Space Suit for Human Pressurized Space Suit Donning Tests

The suitport concept has been recently implemented as part of the small pressurized lunar rover (Currently the Space Exploration vehicle, or SEV) and the Multi-Mission Space Exploration Vehicle (MMSEV) concept demonstrator vehicle. Suitport replaces or augments the traditional airlock function of a spacecraft by providing a bulkhead opening, capture mechanism, and sealing system to allow ingress and egress of a space suit while the space suit remains outside of the pressurized volume of the spacecraft. This presents significant new opportunities to EVA exploration in both microgravity and surface environments. The suitport concept will enable three main improvements in EVA by providing reductions in: pre-EVA time from hours to less than thirty minutes; airlock consumables; contamination returned to the cabin with the EVA crewmember. To date, the first generation suitport has been tested with mockup suits on the rover cabins and pressurized on a bench top engineering unit. The work on the rover cabin has helped define the operational concepts and timelines, and has demonstrated the potential of suitport to save significant amounts of crew time before and after EVAs. The work with the engineering unit has successfully demonstrated the pressurizable seal concept including the ability to seal after the introduction and removal of contamination to the sealing surfaces. Using this experience, a second generation suitport was designed. This second generation suitport has been tested with a space suit prototype on the second generation MMSEV cabin, and testing is planned using the pressure differentials of the spacecraft. Pressurized testing will be performed using the JSC B32 Chamber B, a human rated vacuum chamber. This test will include human rated suitports, a suitport compatible prototype suit, and chamber modifications. This test will bring these three elements together in the first ever pressurized donning of a rear entry suit through a suitport. This paper presents the design of a human rated second generation suitport, the design of a suit capable of supporting pressurized human donning through a suitport, ambient pressure testing of the suit with the suitport, and modifications to the JSC human rated chamber B to accept a suitport. Design challenges and solutions, as well as compromises required to develop the system, are presented. Initial human testing results are presented.

Boyle, Robert M.↗

DOE OSTI2021

Alteration of Fractured Foamed Cement Exposed to CO2-Saturated Water: Implications for Well Integrity

Geologic CO2 storage (GCS) is a method to mitigate the adverse impact of global climate change. Potential leakage of CO2 from fractured cement at the wellbore poses a risk to the feasibility of GCS. Foamed cement is widely applied in deepwater wells where fragile geologic formations cannot support the weight of conventional cement. Thus, it is critical to know whether fractures in foamed cement self-seal in a similar manner as conventional cement systems. This study is the first to investigate the changes in physical and chemical attributes of foamed cement under dynamic flow conditions using CO2-saturated water. Self-sealing of fractures in the cement was observed at a solution flow rate of 0.1 mL/min and a pressure of 6.9 MPa. The formation of CaCO3 precipitates in pore spaces and fractures led to a decrease in permeability by 1 order of magnitude. The extents of self-sealing in foamed cement samples, specifically the 20 and 30% air volume formulations, were similar to that of conventional cements. We attribute this to the greater alteration depth in the foamed cement, which compensated for the reduced availability of Portlandite and higher initial porosity. The results can be used to evaluate the risk of leakage associated with foamed cement.

Geologcial Carbon Storage, Well Integrity in CO2 S↗

NASA NTRS1988

The meteorological measurement system on the NASA ER-2 aircraft

A Meteorological Measurement System (MMS) was designed for the high-altitude ER-2 aircraft (NASA 706). Through dedicated instrumentation installed on the aircraft and repeated calibrations, the MMS provides accurate in situ measurements of free-stream pressure, temperature, and the wind vector. The MMS has participated in two major high-altitude scientific expeditions, the Stratosphere-Troposphere Exchange Project (STEP) based in northern Australia and the Airborne Antarctic Ozone Experiment (AAOE) based in southern Chile. Key MMS subsystems are described. The MMS consists of a dedicated inertial navigation system (INS), a randome differential pressure system, a data acquisition system, and air data instrumentation. The MMS incorporates a high-resolution INS (Litton LIN-72RH model), which is specially configured and is updated at 25 Hz. The differential pressure system, consisting of two sets of pressure ports and transducers, is installed in the ER-2 radome to provide sensitive measurements of the airflow angles (angle of attack and angle of sideslip). The data acquisition system was designed to meet aircraft requirements of compactness and light weight (2 cu ft 50 lb) and for MMS requirements to sample, control, process, and store 45 parameters (some redundant) at a sampling rate up to 10 Hz. The MMS data are stored both in a tape recorder (20 MB) and a hermatically-sealed winchester hard disc (10 MB). Special and redundant instrumentation for temperature and pressure measurements were also installed on the aircraft.

Scott, Stan G.↗

NASA NTRS1978

Gas Control System for HEAO-B

The HEAO-B Gas Control System consists of a high pressure gas storage supply together with distribution and regulation assemblies and their associated electronics for management of gas required for HEAO-B X-ray counter experiments. The Gas Control System replenishes a gas mixture (82 percent argon, 12.3 percent carbon dioxide, 5.7 percent xenon) in the counter volumes which is lost by: diffusion through controlled leakage plugs, diffusion through counter windows, and consumption resulting from periodic purges. The gas density in each counter volume is maintained constant to within 0.25 percent by comparison with a sealed reference volume. The system is fully redundant, capable of operating at atmospheric pressure as well as in a vacuum, contains interlocks which shut down gas flow in the event of either leakage or excessive pressure, and is able to shut down counter high voltage if counter pressure is abnormally low. The system is electronically controlled by ground command and self-sustaining in orbit for a period of at least one year.

Taylor, B.↗

DOE OSTI2022

WIRE-21 Sensor Irradiation Experiment Ready for HFIR Insertion

The ability to deploy new nuclear fuels for current or future reactor concepts requires a wealth of data regarding fuel performance during normal operation, anticipated operational occurrences, and design-basis accidents. Most of these data have historically been collected during experiments in materials test reactors, ideally with online instrumentation to collect as much data as possible. However, advanced instrumentation could also allow for in situ monitoring of fuel operating conditions during commercial reactor operation to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator understanding of limiting peaking factors. The latter approach would complicate fuel handling, particularly during refueling, unless the instrumentation could be placed inside the fuel rods and transmitted wirelessly to a receiver located outside the fuel’s primary pressure boundary. To this end, Westinghouse Electric Company (WEC) developed wireless sensors based on inductive coupling that can transmit information regarding fuel centerline temperatures and rod internal pressures wirelessly from within a fuel rod to a nearby instrument thimble. After testing these sensors in lower-power university research reactors, the next step is to perform high neutron fluence testing to characterize the performance of these wireless sensors under conditions that are more representative of the intended application—in this case, light-water reactors (LWRs). The removable Be (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) provide the neutron flux, experiment volume, and access to instrument leads required to achieve these sensor testing goals. This report summarizes the design, analysis, and assembly of the Wireless Instrumented RB Experiment 2021 (WIRE-21). This is the most highly instrumented irradiation experiment ever performed in HFIR. The experiment will use seven different sensing techniques to measure temperature, pressure, neutron flux, and neutron fluence during reactor operation. In addition to WEC’s wireless temperature and pressure sensors, WIRE-21 includes an array of thermocouples, self-powered neutron detectors, spatially distributed fiber optic temperature sensors, passive SiC temperature monitors, and flux wires. The design of WIRE-21 and the cabling that was installed in HFIR also provide the infrastructure to enable accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting component temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) that would be expected in the plenum region of LWR fuels, except for the active sensing region of the wireless temperature sensor, which is targeting LWR fuel centerline temperatures (~800–1,100°C). WIRE-21 was successfully assembled, passed all nondestructive examination, and was delivered to HFIR for insertion during upcoming cycle 498 (April 2022).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗