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DOE OSTI2023

PipeSight: A High-Performance Computing Platform for Pipeline Integrity Management

The Phase I feasibility study completed as part of this project has led to a number of innovative technologies being developed and has laid the foundation for a successful Phase II effort to commercialize a platform for managing the integrity of pipelines for the damage mechanisms of the new, hybrid-energy based economy. To ground the development efforts and direction of the project, an extensive market research and customer discovery effort was undertaken early in Phase I. Through this effort, a number of pipeline owners and operators were interviewed, and the following key findings were discovered about the pipeline industry: • Small pipeline operators do not have the central engineering groups necessary to perform their own independent analysis of inspection data, but instead rely on summarized tally sheets provided to them by inspection service providers. • The time it takes to go from an inspection to a completed engineering assessment, even for small segments of pipeline, can take anywhere from 30-120 days. During this delay, critical threats can (and have been known to) cause failures. • Uncertainty is often not accounted for in the assessment of pipeline integrity. The tally sheets provided by third-party service providers are almost always deterministic in nature, identifying threats that present a concern only to the current (not the future) integrity of the pipeline. • It is uncommon to apply the latest technologies to perform advanced assessments of damaged pipelines. There is a desire to use more advanced analysis capabilities to assess threats. Many pipeline operators indicated that they would often excavate a pipeline to perform an inspection and find that the damage was not as bad as they anticipated, thus using limited resources unnecessarily. Companies are not consistent in their use of inspection data to determine corrosion rates, and those that do only calculate deterministic corrosion rates. • The industry has prominently relied on time-based inspections but has recently started to transition to risk-based inspections. However, there appears to be no uniform guidance on how to do so while properly accounting for all sources of uncertainty. • Companies are not storing inspection data in a manner that allows for the ready determination of temporal trends. • Predictive maintenance principles and practices are beginning to be used by early adopters • Some pipelines are being re-purposed to transport different process fluids than they were designed for, e.g., H 2 and CO 2 rich process streams to serve the new hybrid-energy based economy, which are presenting new integrity concerns for the existing pipeline network that crisscrosses the United States. As a result of these discoveries, we were able to target the development efforts in Phase I to best serve the needs of the industry. In Phase I, we developed a way to correlate multiple large-scale scans of the pipeline to determine a probabilistic corrosion rate that accounts for all sources of error and uncertainty in the inspection process. This probabilistic corrosion rate can be used to predict the future thickness distribution of the pipe wall. We demonstrate how this analysis may be performed in an analytical fashion and has been implemented in such a manner that it can be readily distributed using GPU computing through integration of the Kokkos programming model. We also make a very novel extension of the analytical corrosion rate model to Bayesian Networks (an explainable AI technique) that can account for non-parametric distributions of corrosion rates. With the predictions made above for the probabilistic corrosion rate and corresponding future distribution of the pipe wall thickness, we can assess the integrity of the pipeline through the use of a probabilistic engineering assessment. We developed a novel screening data analysis approach that can rapidly identify ‘hotspots’ (local thin areas) where the integrity of the pipeline is a concern. Once more, we implemented this screening approach in C++ to leverage GPU computing via the Kokkos programming model. After the critical hotspots are identified, we developed a program that can automatically generate an advanced finite element model of the damaged regions. Since the number of damaged regions that require advanced analysis can number in the thousands, we integrated an open-source container-native workflow engine for orchestrating parallel jobs on the cloud. Initially, these advanced numerical models were only designed to account for loading due to internal pressure. However, in a slight pivot from the initial Phase I proposal, we developed a complete pipe stress analysis program (called Simflex) which can simulate the complete pipeline and its response to thermal expansion, pressure, thermal bowing, weight, wind, earthquake, support displacement, support friction and external forces. This pipe stress analysis program was written generically, to handle any piping system, but contains the features needed to model long pipelines (i.e., it incorporates a model for soil mechanics and can account for the nonlinear boundary conditions necessary to simulate long underground pipelines). This pipe stress analysis program can simulate any segment of the pipeline (simple or complex) under any set of conditions and loads, to determine the supplemental loads (axial forces and bending moments) at the location of damage. This enables the most accurate state of stress to be accounted for in the pipeline, which can prove critical when evaluating the integrity of a damaged region. In the process of developing the technologies to perform the integrity assessment of the pipeline, we also extended one of the industry standard approaches for performing the assessment of local thin areas that extend more in the circumferential direction than the longitudinal direction of the pipeline. This approach was presented to the API 579-1/AS ME FFS-1 steering committee in November 2021 for consideration in the next edition of the industry standard for Fitness-For-Service (expected to be released in 2023). To help pipeline operators make decisions with the results on any integrity assessment, we developed a new approach to the life-cycle management of pipelines which uses a Bayesian Decision Network. The network is designed to help pipeline operators plan and prioritize inspection activities and ultimately make smarter, more cost-effective decisions. The Bayesian approach accounts for all sources of uncertainty and carries them through to the final optimal decisions, providing a probabilistic framework for optimizing inspection intervals. The proof-of-concept networks developed in the feasibility study are complete, verified, and are focused on a subset of the pipeline. To expand this novel approach to the scale necessary for an entire network of pipelines in Phase II, we will leverage the DOE-funded Bengi solver for industrial-scale decision making with Bayesian Networks [22]. Once implemented, we will be able to provide the pipeline industry with a much-needed tool for optimal inspection planning using truly explainable artificial intelligence (XAI). To handle all of these advanced capabilities into a cloud-based platform, the architecture of the Equity Engineering Cloud (EEC) was extended to include Argo Workflows, a framework capable of distributing and managing a massive number of jobs that consume their own resources, such that thousands of serial finite element simulations can be run in parallel. As part of this substantial undertaking, we also integrated Argo Continuous Delivery (CD) into the EEC, to aid with the rapid prototyping and iterations that will be imperative to the success of the PipeSight platform’s Agile development process in Phase II. As part of the pipe stress analysis program, we also developed a custom visualizer that leverages the DOE-funded VTK visualization library. We added custom contouring capabilities and a means for interacting visually with both the inputs and outputs of the pipe stress analysis program. We also developed routines for automating the post-processing of the finite element simulations to determine if any failure criteria are met and to visualize the deformations, stresses and strains in ParaView using the exodus II file format (a subset of netCDF).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Fortifying Environmental Compliance Strategies at Hanford - 19541

At the Hanford Site, located near Richland, Washington, the Department of Energy is cleaning up legacy radioactive and mixed-waste generated from the Manhattan Project in the 1940's. A major component of cleaning up the waste is maintaining compliance with federal and state environmental regulations. Environmental compliance is also determined through permits, agreements, and consent orders issued by regulating agencies such as the Washington State Department of Health: Office of Radiation Protection, Washington State Department of Ecology Nuclear Waste Program, and the Environmental Protection Agency. Maintaining compliance at Hanford reduces environmental impacts and addresses violations, or non-compliances. The following strategies improve compliance and support the avoidance of enforcement actions. At Hanford, regulatory agency environmental enforcement actions, and their corrective actions, are tracked to completion using databases maintained by inspection subject matter experts. The databases are used to provide the Department of Energy and contractor management with up-to-date status of regulatory agency activity and the required corrective actions. Trending enforcement actions helps target compliance vulnerabilities. Findings and corrective actions that are entered into the databases are then trended by date, location, responsible contractor, agency, and type of compliance issue. The ability to review previous non-compliances in certain locations of the Site, or by general alleged violation, provides the project's environmental contacts with information on what types of issues to look for on pre-inspection walk downs. Finding non-compliances during pre-inspection walk downs allows the contractor to correct the issue and avoid potential fines from regulating agencies. The walk downs are conducted by environmental specialists and project personnel looking for issues that may be viewed as a compliance problem. Using agency checklists and previous inspection correspondence can help to provide valuable information during pre-inspection activities. Training regulatory agency inspectors on Site security requirements, cultural and ecological standards, and inspection protocols allows for increased efficiency and reduces potential miscommunication between regulatory agencies and the regulated contractors. The training also allows the contractors to give the regulating agencies the up-to-date policies and procedures that will be addressed during the inspection. Hanford has pre-identified inspection coordinators within each contractor to assist in coordinating with Department of Energy personnel, projects, and management prior to the inspections. These inspection coordinators notify affected management, accommodate and escort the regulators to locations they ask to inspect, set up requested interviews, and gather requested information that will need to be cleared for public release. These practices make for positive experiences and interactions with the regulating agency personnel and help reduce and eliminate environmental non-compliances, findings, violations, and fines. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

A Lizard-inspired Tube Inspector (LTI) Robot

This final report summarizes the research findings of the current project. This project is a collaboration between New Mexico State University (NMSU) as a lead (Recipient) and Arizona State University (ASU) as a Co-Recipient. Tubular structures are common components of boilers and heat exchangers in power plants. Over time, these components may suffer corrosion, cracks, and stress-corrosion cracks in either the body or the welded connections. A single tube leakage can cause an outage of several weeks. Regular inspection is a key safety factor when ensuring that power plants are maintained in reliable, operational condition. This inspection, however, is challenging, time-consuming, and in many cases impossible due to accessibility issues and safety concerns. Recent developments in robotic-based inspection can offer a great solution. Hard-to-reach places can be inspected without overhauling the unit, saving time and cost. Although several robots have been designed and implemented successfully for inspecting power plant components, in particular tubular structures, their mobility and flexibility are limited. Most of these robots use wheels for mobility which reduces their maneuverability of these robots. Moreover, they usually use magnets to attach to tubes which will not work on tubes with non-ferromagnetic materials. These robots usually carry measurement tools for a particular non-destructive testing (NDT) method such as ultrasound testing (UT) that requires a couplant to perform a point-by-point (scanning) inspection of the tubular structure. In this project, we developed a versatile lizard-inspired tube inspector (LTI) robot with embedded inspection sensing components for tube inspection which removes the need for point-by-point scanning of tube surface for crack and corrosion detection. Inspired by a “lizard”, the novelty of the current project is the integration of couplant-free ultrasound sensing and transmission, advanced data-driven defect detection and imaging, and friction-based mechanical mobility components in a single robot to eliminate a need for smooth surfaces and simple geometry for mobility and scanning. The LTI robot could replace the wheel-based approach with friction-based mobility to significantly increase the flexibility and maneuverability of the robot. The LTI robot can get into a power plant unit, such as a boiler, from a small area allowing it to access a component of interest for inspection (e.g., move on OD, curved and flat surfaces, non-ferromagnetic or ferromagnetic materials, and tubes with rough surfaces and complex geometries). Additionally, an advanced data-driven method using ultrasound data was pioneered to allow the robot to detect defects in the entire area between the robot’s multi-functional mobility system (grippers). Integrating a couplant-free ultrasound sensing in the robot’s grippers as well as using advanced data-driven methods allowed the LTI to detect defects in the entire cross-section of a tube using its grippers when stationary and when mobile.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2012

Post-Closure Report for Closed Resource Conservation and Recovery Act Corrective Action Units, Nevada National Security Site, Nevada for Fiscal Year 2011 (October 2010-September 2011)

This report serves as the combined annual report for post-closure activities for the following closed Corrective Action Units (CAUs): • CAU 90, Area 2 Bitcutter Containment; • CAU 91, Area 3 U-3fi Injection Well; • CAU 92, Area 6 Decon Pond Facility; • CAU 110, Area 3 WMD U-3ax/bl Crater; and • CAU 112, Area 23 Hazardous Waste Trenches. This report covers fiscal year 2011 (October 2010-September 2011). The post-closure requirements for these sites are described in Resource Conservation and Recovery Act Permit Number NEV HW0101 and summarized in each CAU-specific section in Section 1.0 of this report. Site inspections are conducted semiannually at CAUs 90 and 91 and quarterly at CAUs 92, 110, and 112. Additional inspections are conducted at CAU 92 if precipitation occurs in excess of 0.50 inches in a 24-hour period. Inspections include an evaluation of the condition of the units and identification of any deficiencies that may compromise the integrity of the units. The condition of covers, fencing, signs, gates, and locks is documented. In addition, soil moisture monitoring and subsidence surveys are conducted at CAU 110. The results of the inspections, summary of maintenance activities, results of vegetations surveys, and analysis of monitoring data are presented in this report. Copies of the inspection checklists are included as Appendix A. Field notes completed during each inspection are included in Appendix B. Photographs taken during the inspections are included in Appendix C. It is recommended to continue semiannual inspections at CAUs 90 and 91; quarterly inspections at CAUs 92, 110, and 112; and additional inspections at CAU 92 if precipitation occurs in excess of 0.50 inches in a 24-hour period. At CAU 92, it is recommended to remove the wave barriers, as they have not proven to be necessary to protect the cover. At CAU 110, it is recommended to continue annual vegetation monitoring and soil moisture monitoring, and to reduce the frequency of subsidence surveys from twice per year to once every other year (biennially).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Use of Unmanned Aerial Systems for Post-closure Waste Site Maintenance and Surveillance - 20143

The P- and R-Area Reactor buildings, located at SRS near Aiken, SC, were in-situ decommissioned by grouting below-grade portions of the buildings and demolishing some above-grade structures to grade level. Other reactor building structures were left above-grade and sealed to prevent human or animal access. Because the above grade-structures are expected to continue in their present state for hundreds of years, the condition of the building roofs is critical to mitigate rainwater intrusion. For this reason, building roof areas were strengthened with high strength concrete to ensure the long-term integrity of the roof structure. Periodic inspections of the roof structures are required to ensure that the roofs are functioning properly and to identify damage areas. The traditional method of inspecting closed reactor buildings requires the use of a helicopter and photographer to generate photographs and videos for review. This method proved sufficient but lacked the resolution and clarity that is required for a thorough inspection of the building structure. Fortunately, the Savannah River National Laboratory (SRNL) has established a Small Unmanned Aircraft System (sUAS) program using commercially available and custom-built remote-controlled aircraft. EC and ACP contacted the SRNL program to evaluate whether the sUAS technology could be employed for periodic reactor building inspections. The sUAS can fly within a few meters of the reactor buildings and hover, allowing for a more thorough aerial inspection. The initial sUAS inspection of the P-Area Reactor building was completed in February 2018 and at the R-Area Reactor building in August 2018 and were successful in providing higher resolution photos and videos. The sUAS inspections also revealed that vegetation had begun to grow on the roofs that could potentially damage the structure integrity. SRNL partnered with Virginia Polytechnic Institute and State University to build a custom heavy lift sUAS that could be equipped with herbicides to remotely treat the vegetative growth. Herbicides were successfully applied to the R-Area Reactor building roof using the custom sUAS in September 2018. The use of unmanned aircraft systems at SRS to perform aerial inspections and herbicide treatment in otherwise inaccessible areas has proven to be an efficient and cost-effective technology that provides high value, increases knowledge of facility conditions, and provides for early detection of damage. Periodic inspections of the reactor building roofs using sUAS technology are performed safely, efficiently, and at a significant cost and schedule savings while reducing emissions, noise, and fossil fuel use. The use of sUAS equipment for building inspections and herbicide application at SRS is unique within the DOE complex. The goal of SRS is to apply this remote technology to other waste unit operations and maintenance activities in the future. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

Preliminary Thermal Modeling of HI-STORM 100 Storage Modules at Diablo Canyon Power Plant ISFSI

Thermal analysis is being undertaken at Pacific Northwest National Laboratory (PNNL) in support of inspections of selected storage modules at various locations around the United States, as part of the Used Fuel Disposition Campaign of the U.S. Department of Energy, Office of Nuclear Energy (DOE-NE) Fuel Cycle Research and Development. This report documents pre-inspection predictions of temperatures for two modules at the Diablo Canyon Power Plant ISFSI identified as candidates for inspection. These are HI-STORM 100 modules of a site-specific design for storing PWR 17x17 fuel in MPC-32 canisters. The temperature predictions reported in this document were obtained with detailed COBRA-SFS models of these storage systems, with the following boundary conditions and assumptions. • storage module overpack configuration based on FSAR documentation of HI-STORM100S-218, Version B; due to unavailability of site-specific design data for Diablo Canyon ISFSI modules • Individual assembly and total decay heat loadings for each canister, based on at-loading values provided by PG&E, “aged” to time of inspection using ORIGEN modeling - Special Note: there is an inherent conservatism of unquantified magnitude – informally estimated as up to approximately 20% -- in the utility-supplied values for at-loading assembly decay heat values • Axial decay heat distributions based on a bounding generic profile for PWR fuel. • Axial location of beginning of fuel assumed same as WE 17x17 OFA fuel, due to unavailability of specific data for WE17x17 STD and WE 17x17 Vantage 5 fuel designs • Ambient conditions of still air at 50°F (10°C) assumed for base-case evaluations - Wind conditions at the Diablo Canyon site are unquantified, due to unavailability of site meteorological data - additional still-air evaluations performed at 70°F (21°C), 60°F (16°C), and 40°F (4°C), to cover a range of possible conditions at the time of the inspection. (Calculations were also performed at 80°F (27°C), for comparison with design basis assumptions.) All calculations are for steady-state conditions, on the assumption that the surfaces of the module that are accessible for temperature measurements during the inspection will tend to follow ambient temperature changes relatively closely. Comparisons to the results of the inspections, and post-inspection evaluations of temperature measurements obtained in the specific modules, will be documented in a separate follow-on report, to be issued in a timely manner after the inspection has been performed.

Site Inspection↗
DOE OSTI2013

Using Mobile Agents and Overlay Networks to Secure Electrical Netoworks

ABSTRACT The use of wandering, mobile agents can provide a robust approach for managing, monitoring, and securing electrical distribution networks. However, the topological structure of electrical networks can affect system performance. For example, if the multi-agent system relies on a regular inspection rate (on average, points of interest are inspected with equal frequency), then locations that are not well connected will on average be inspected less frequently. This paper discusses creation and use of overlay networks that create a virtual grid graph can provide faster coverage and a more uniform average agent sampling rate. Using overlays agents wander a virtual neighborhood consisting of only points of interest that are interconnected in a regular fashion (each point has the same number of neighbors). Experimental results will show that an overlay can often provide better network coverage and a more uniform inspection rate, which can improve cyber security by providing a faster detection of threats

Dawes, Neal A.↗
DOE OSTI2014

A Quantitative Assessment of Advanced NDI Techniques for Detecting Flaws in Composite Laminate Aircraft Structures. Draft

The aircraft industry continues to increase its use of composite materials, most noteworthy in the arena of principle structural elements. This expanded use, coupled with difficulties associated with damage tolerance analysis of composites, has placed greater emphasis on the application of accurate nondestructive inspection (NDI) methods. Traditionally, a few ultrasonic-based inspection methods have been used to inspect solid laminate structures. Recent developments in more advanced NDI techniques have produced a number of new inspection options. Many of these methods can be categorized as wide area techniques that produce two-dimensional flaw maps of the structure. An experiment has been developed to assess the ability of both conventional and advanced NDI techniques to detect voids, disbonds, delaminations, and impact damage in adhesively bonded composite aircraft structures. A series of solid laminate, carbon composite specimens with statistically relevant flaw profiles are being inspected using conventional, hand-held pulse echo UT and resonance, as well as, new NDI methods that have recently been introduced to improve sensitivity and repeatability of inspections. The primary factors affecting flaw detection in laminates are included in this study: material type, flaw profiles, presence of complex geometries like taper and substructure elements, presence of fasteners, secondarily bonded joints, and environmental conditions. One phase of this effort utilized airline personnel to study Probability of Detection (POD) in the field and to formulate improvements to existing inspection techniques. In addition, advanced NDI methods for laminate inspections — such as thermography, shearography, laser ultrasonics, microwave, and phased/linear array UT — were applied to quantify the improvements achievable through the use of more sophisticated NDI. This report presents the composite laminate experiment design and the POD results for advanced NDI with comparisons to results achieved by airline inspectors using conventional UT methods. A companion report provides the full set of results from the conventional NDI testing.

36 MATERIALS SCIENCE↗
NASA NTRS1999

The Effect of Penetration Depth on Thermal Contrast of NDT by Thermography

Nondestructive evaluation by Thermography (TNDE) is generally classified into two categories, the passive approach and the active approach. The passive approach is usually performed by measuring the natural temperature difference between the ambient and the material or structure to be tested. The active approach, on the other hand, requires the application of an external energy source to stimulate the material for inspection. A laser, a heater, a hot air blower, a high power thermal pulse, mechanical, or electromagnetic energy may provide the energy sources. For the external heating method to inspect materials for defects and imperfection at ambient temperature, a very short burst of heat can be introduced to one of the surfaces or slow heating of the side opposite to the side being observed. Due to the interruption of the heat flow through the defects, the thermal images will reveal the defective area by contrasting against the surrounding good materials. This technique is called transient Thermography, pulse video Thermography, or thermal wave imaging. As an empirical rule, the radius of the smallest defect should be at least one to two times larger than its depth under the surface. Thermography is being used to inspect void, debond, impact damage, and porosity in composite materials. It has been shown that most of the defects and imperfection can be detected. However, the current method of inspection using thermographic technique is more of an art than a practical scientific and engineering approach. The success rate of determining the defect location and defect type is largely depend on the experience of the person who operates thermography system and performs the inspection. The operator has to try different type of heat source, different duration of its application time, as well as experimenting with the thermal image acquisition time and interval during the inspection process. Further-more, the complexity of the lay-up and structure of composites makes it more difficult to determine the optimal operating condition for revealing the defects. In order to develop an optimal thermography inspection procedure, we must understand the thermal behavior inside the material subjected to transient heat in order to interpret the thermal images correctly. Fabrication of finite element models of characteristic defects in composite materials subjected to transient heat will enable the development of appropriate procedure for thermography inspection. Design of phantom defects could be modeled and behavior characterized prior to physically building these test parts. Since production of phantom test parts can be very time consuming and laborious, it is important to design good representative defects.

Chu, Tsuchin Philip↗
DOE OSTI2019

Savannah River Site H-Canyon Collaborative Advanced Technology Demonstration (ATD) Program Review - 19499

The purpose of the Department of Energy-Environmental Management Office of Technology Development's (DOE-EM TD) Science of Safety (SOS) Robotics Initiative is to pull innovative commercial off the shelf (COTS) and near ready technologies to the field to expedite remaining EM mission clean up and enhance worker safety. A goal of this program is to demonstrate to DOE facilities the value of these available new technologies and their potential uses to solve difficult problems. In support of this goal, the Savannah River Site (SRS) H-Canyon Air Exhaust (HCAEX) tunnel biannual inspection task has been selected to demonstrate and evaluate the benefit of pulling advanced technology solutions to EM facilities. This is a highly collaborative task facilitated by SRNL and engaging SRS H-Canyon facility stakeholders, National Laboratory robotic and concrete inspection SMEs and university robotic and sensor researchers. Presently, the SRS HCAEX tunnel inspection consists of a visual examination to evaluate the structural integrity of the tunnel. Personal access is prohibited in the tunnel due to extreme conditions, thus the examination is accomplished remotely by deploying cameras mounted on a robotic crawler deployed into the tunnel. While the ability to see inside the tunnel in recent years has been highly valuable, it is desirable to have a better understanding of the environment to support a more thorough structural analysis and for long term planning purposes. This higher order of understanding can be accomplished through advanced COTS sensors and tools and those currently in development and near ready. The advanced technologies selected for demonstration will be evaluated for hosting on the FY19 HCAEX tunnel inspection crawler platform. The HCAEX ATD task is expected to be performed over a two-year period with year one now concluding. At WM2018, we presented the H-Canyon stakeholder's high priority inspection and remote handling needs, the collaboration team and the planned process of developing an integrated solution. This presentation will review the initial scope and inspection needs, then discuss the past year's progress to address these needs. The discussion includes the results of the Concrete Integrated Product Team (CIPT) formed to evaluate promising concrete NDE inspection technologies and a Lidar based tunnel mapping sensor suite solution. Highlighted in the discussion will be the engagement and pulling of university developed research and development to include student engagement through the formation and hosting of the SRNL Robotics and Sensors Intern team and collaboration with MSIPP funded Robotic Arm Concrete NDT Inspection University researchers. Lastly, the path forward to complete the demonstration will be presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

3D model generation using an airborne swarm

Using an artificial kinematic field to provide co-ordination between multiple inspection UAVs, the authors herein demonstrate full 3D modelling capability based on a photogrammetric system. The operation of the system is demonstrated by generating a full 3D surface model of an intermediate level nuclear waste storage drum. Such drums require periodic inspection to ensure that drum distortion or corrosion is carefully monitored. Performing this inspection with multiple airborne platforms enables rapid inspection of structures that are inaccessible to on-surface remote vehicles and are in human-hazardous environments. A three-dimensional surface-meshed model of the target can then be constructed in post-processing through photogrammetry analysis of the visual inspection data. The inspection environment uses a tracking system to precisely monitor the position of each aerial vehicle within the enclosure. The vehicles used are commercially available Parrot AR. Drone quadcopters, controlled through a computer interface connected over an IEEE 802.11n (WiFi) network, implementing a distributed controller for each vehicle. This enables the autonomous and distributed elements of the control scheme to be retained, while alleviating the vehicles of the control algorithm’s computational load. The control scheme relies on a kinematic field defined with the target at its centre. This field defines the trajectory for all the drones in the volume relative to the central target, enabling the drones to circle the target at a set radius while avoiding drone collisions. This function enables complete coverage along the height of the object, which is assured by transitioning to another inspection band only after completing circumferential coverage. Using a swarm of vehicles, the time until complete coverage can be significantly reduced.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Patterning approach for detecting defect in device manufacturing

Compact handheld devices which were a dream in the past are now a reality; this has been enabled by miniaturization of circuit architectures including power devices. Scaling down of the design feature sizes does come with a price with an increase in systematic defects during chip manufacturing. There are generally two methods of inline defect detection adopted to monitor the semiconductor device fabrication—optical inspection and electron beam inspection. The optical inspection uses ultra-violet and deep ultra-violet (UV/DUV) light to find patterning defects on the wafer. While the electron-beam inspection uses electron charge and discharge measurement to find electrical connection defects, both are a costly procedure in terms of resources and time. The physical limit of feature resolution of the optical source is now making the defect inspection job difficult in miniaturized application specific integrated circuit (ASIC). This study is designed to test the patterning optimization approach on both inspection platforms. Using hotspot analysis weak locations are identified in the full chip design, and then they are verified in the inline wafer inspection. The criterion for hot-spot determination is also discussed in this paper.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Management and Operation of the Oak Ridge National Laboratory

ThermaMatrix, Inc provides novel vision inspection solutions for a wide range of manufacturers and industries, providing and implementing the leading technologies for nondestructive inspection (NDI) and material characterization. Many other inspection solutions are either not adequate or are not approachable due to implementation barriers needing expert level operators, excessive inspection time, and high cost. ThermaMatrix’sadvanced vision inspection technology addresses all of these limitations. The Lab Embedded Entrepreneurial Program (LEEP) opportunity by the Department of Energy (DOE) allows small-business start-ups to leverage national laboratory capabilities and skilled scientists to rapidly develop their technology that aligns with DOE goals. ThermaMatrix, Inc.was positioned in the Innovation Crossroads program at Oak Ridge National Laboratory to further develop thenovel Watson Vision Inspection System to support manufacturing quality control efforts. Theresearch goals were (1) explore fundamental parameters that would improve preexisting capabilities, (2) full-scale industrial setup for demonstration, and (3) capability testing and verification. Manufacturing is demanding more NDI implementation to support their quality control needs, which this technology development would support. Figure 1: Ryan Spencer of ThermaMatrix with Watson Vision Inspection System.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS2012

Reliability of High I/O High Density CCGA Interconnect Electronic Packages under Extreme Thermal Environment

This paper provides the experimental test results of advanced CCGA packages tested in extreme temperature thermal environments. Standard optical inspection and x-ray non-destructive inspection tools were used to assess the reliability of high density CCGA packages for deep space extreme temperature missions. Ceramic column grid array (CCGA) packages have been increasing in use based on their advantages such as high interconnect density, very good thermal and electrical performances, compatibility with standard surface-mount packaging assembly processes, and so on. CCGA packages are used in space applications such as in logic and microprocessor functions, telecommunications, payload electronics, and flight avionics. As these packages tend to have less solder joint strain relief than leaded packages or more strain relief over lead-less chip carrier packages, the reliability of CCGA packages is very important for short-term and long-term deep space missions. We have employed high density CCGA 1152 and 1272 daisy chained electronic packages in this preliminary reliability study. Each package is divided into several daisy-chained sections. The physical dimensions of CCGA1152 package is 35 mm x 35 mm with a 34 x 34 array of columns with a 1 mm pitch. The dimension of the CCGA1272 package is 37.5 mm x 37.5 mm with a 36 x 36 array with a 1 mm pitch. The columns are made up of 80% Pb/20%Sn material. CCGA interconnect electronic package printed wiring polyimide boards have been assembled and inspected using non-destructive x-ray imaging techniques. The assembled CCGA boards were subjected to extreme temperature thermal atmospheric cycling to assess their reliability for future deep space missions. The resistance of daisy-chained interconnect sections were monitored continuously during thermal cycling. This paper provides the experimental test results of advanced CCGA packages tested in extreme temperature thermal environments. Standard optical inspection and x-ray non-destructive inspection tools were used to assess the reliability of high density CCGA packages for deep space extreme temperature missions. Keywords: Extreme temperatures, High density CCGA qualification, CCGA reliability, solder joint failures, optical inspection, and x-ray inspection.

high density CCGA qualifications↗
DOE OSTI2018

Aging Management Considerations for Dry Cask Storage Canisters - 18472

Dry cask storage systems (DCSSs) are used to store used nuclear fuel (UNF) at independent spent fuel storage installations (ISFSIs) prior to final geologic storage or reprocessing. As storage durations increase beyond the twenty-year period commonly implemented for licensing the storage sites, it is important to consider aging related degradation issues for DCSS components. A large portion of the DCSS designs used throughout the world employ a ventilated concrete overpack with a welded stainless steel canister that confines the UNF. This paper explores key issues related to aging management for these canister components, including: (1) canister environment, (2) inspection limitations, and (3) aging management program guidance and requirements. While the austenitic stainless steel used for the canisters are generally resistant to most forms of environmental attack, it is possible for conditions to arise that lead to pitting and even stress corrosion cracking of the canister systems. A large number of studies related to canister degradation have been performed by industry groups and government researchers, both in the US and worldwide. These advances in the collective knowledge provide insight into risk factors for DCSS. Such information is beneficial to improve ISFSI siting decisions and ensure successful relicensing of existing ISFSIs. This paper highlights relevant research and also discusses applicability to degradation of other equipment and containers used to process and isolate UNF and other nuclear waste streams from the public and the environment. Inspection of the canister surface is an important tool to investigate and evaluate the potential for degradation. Existing DCSS designs typically do not offer ready access to the canister surface in order to perform the inspection. Further complicating inspection efforts are the surface conditions present on the sheltered canisters after extended storage times, including atmospheric debris such as dust and pollen. Given ongoing development efforts, inspection capabilities and associated limitations should be assessed at multiple points in time over the course of an aging management program to incorporate new advances in the field. This paper explores the limitations of currently available capabilities in inspection and delivery, and provides insight into the gaps remaining to be filled to permit an effective inspection program. Recommendations and requirements related to programs for aging management of canisters have been published or are in progress from a variety of groups, including industry groups, regulatory authorities, and Codes and Standards. An effective aging management program should consider the technical bases of these various inputs and maintain compliance with requirements. Given multiple sources, decisions will be required when considering conflicting guidance, and this paper will include discussion of the relative merits of the various approaches. (author)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Development of a pseudo phased array technique using EMATs for DM weld testing

Ultrasonic inspection of dissimilar metal (DM) welds in piping with cast austenitic stainless steel (CASS) has been an area ongoing research for many years given its prevalence in the petrochemical and nuclear industries. A typical inspection strategy for pipe welds is to use an ultrasonic phased array system to scan the weld from a sensor located on the outer surface of the pipe. These inspection systems generally refract either longitudinal or shear vertical (SV) waves at varying angles to inspect the weld radially. In DM welds, however, the welding process can produce a columnar grain structure in the CASS material in a specific orientation. This columnar grain structure can skew ultrasonic waves away from their intended path, especially for SV and longitudinal wave modes. Studies have shown that inspection using the shear horizontal (SH) wave mode significantly reduces the effect of skewing. Electromagnetic acoustic transducers (EMATs) are known to be effective for producing SH waves in field settings. This paper presents an inspection strategy that seeks to reproduce the scanning and imaging capabilities of a commercial phase array system using EMATs. A custom-built EMAT was used to collect data at multiple propagation angles, and a processing strategy known as the synthetic aperture focusing technique (SAFT) was used to combine the data to produce an image. Results are shown using this pseudo phased array technique to inspect samples with a DM weld and artificial defects, demonstrating the potential of this approach in a laboratory setting. Recommendations for future work to transition the technique to the field are also provided.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Monitoring Aqueous Reprocessing Systems for Detection of Facility Misuse

Traditional approaches to material control and accounting at used nuclear fuel reprocessing facilities relies in large part on laboratory-based destructive assay of periodic samples taken from key stages. These techniques are highly accurate, but limited inspection frequency may limit the size and operation of a reprocessing facility. Online monitoring techniques using inline detectors can be applied to fuel reprocessing systems to improve the situational awareness as the facility is operating to provide additional indicators of the evolving state of the facility between normal inspection periods, potentially alerting regulators to the need for additional inspection. The Multi-Isotope Process (MIP) Monitor combines medium-resolution gamma detectors with statistical data analysis techniques to monitor reprocessing systems for anomalous conditions resulting from process control issues or malfeasance. Gamma spectra collected from the H-Canyon reprocessing facility were modeled using principal component analysis to demonstrate the efficacy of the MIP Monitor for detecting notional diversion scenarios.

safeguards, nuclear fuel reprocessing, gamma spect↗
DOE OSTI2015

Post-Closure Report for Closed Resource Conservation and Recovery Act Corrective Action Units, Nevada National Security Site, Nevada, for Fiscal Year 2014

This report serves as the combined annual report for post-closure activities for several Corrective Action Units (CAUs). The locations of the sites are shown in Figure 1. This report covers fiscal year 2014 (October 2013–September 2014). The post-closure requirements for these sites are described in Resource Conservation and Recovery Act Permit Number NEV HW0101 and summarized in each CAU-specific section in Section 1.0 of this report. The results of the inspections, a summary of maintenance activities, and an evaluation of monitoring data are presented in this report. Site inspections are conducted semiannually at CAUs 90 and 91 and quarterly at CAUs 92, 110, 111, and 112. Additional inspections are conducted at CAU 92 if precipitation occurs in excess of 0.50 inches (in.) in a 24-hour period and at CAU 111 if precipitation occurs in excess of 1.0 in. in a 24-hour period. Inspections include an evaluation of the condition of the units, including covers, fences, signs, gates, and locks. In addition to visual inspections, soil moisture monitoring, vegetation evaluations, and subsidence surveys are conducted at CAU 110. At CAU 111, soil moisture monitoring, vegetation evaluations, subsidence surveys, direct radiation monitoring, air monitoring, radon flux monitoring, and groundwater monitoring are conducted. The results of the vegetation surveys and an analysis of the soil moisture monitoring data at CAU 110 are presented in this report. Results of additional monitoring at CAU 111 are documented annually in the Nevada National Security Site Waste Management Monitoring Report Area 3 and Area 5 Radioactive Waste Management Sites and in the Nevada National Security Site Data Report: Groundwater Monitoring Program Area 5 Radioactive Waste Management Site, which will be prepared in approximately June 2015. All required inspections, maintenance, and monitoring were conducted in accordance with the post-closure requirements of the permit. It is recommended to continue inspections and monitoring as scheduled.

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