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NASA NTRS2018

Thermal Model Performance for the James Webb Space Telescope OTIS Cryo-Vacuum Test

The James Webb Space Telescope (JWST), set to launch in early 2019, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, has recently been completed at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A system-level pre-test thermal model was constructed which fully captured the behavior of the payload, ground support equipment, and surrounding test chamber. This thermal model simulated both the transient cooldown to and warmup from a 20K flight-like environment, as well as predicted the payload performance at cryo-stable conditions. The current work is a preliminary assessment of thermal model performance against actual payload response during the OTIS CV test. It examines both the benefits and shortcomings of assumptions made pre-test to simplify model execution when compared against test data. It explores in detail the role of temperature-dependent emissivities during transition to cryogenic temperatures, as well as the impact that model geometry simplifications have on tracking of critical hardware limits and constraints. This work concludes with a list of recommendations to improve the accuracy of thermal modeling for future large cryogenic tests. It is hoped that the insight gained from the OTIS CV test thermal modeling will benefit planning and execution for upcoming cryogenic missions.

JWST↗

NASA NTRS2020

Investigation of a Helicopter Individual Blade Control (IBC) System in Two Full-Scale Wind Tunnel Tests: Volume I

This report presents the data acquired during the testing of an individual blade control (IBC) system on a full-scale helicopter rotor in two test entries in the NASA Ames 40- by 80-Foot Wind Tunnel. The objective of these investigations was to evaluate the potential benefits of using IBC to improve rotor performance, reduce blade vortex interaction (BVI) noise, and alleviate helicopter vibrations. The wind tunnel tests were an international, collaborative effort between NASA, the U.S. Army Aeroflightdynamics Directorate, ZF Luftfahrttechnik GmbH, Eurocopter Deutschland GmbH, and the German Aerospace Laboratory (DLR). They were conducted as a task of the U.S./German Memorandum of Understanding (MOU) on Helicopter Aeromechanics. The IBC tests were performed using a full-scale BO-105 helicopter rotor mounted to the NASA/U.S. Army Rotor Test Apparatus (RTA). The first test, performed in 1993, was the first full-scale wind tunnel test to explore the effects of an IBC system on rotor vibration, noise, and performance. In this test, the pitch links of the rotor were replaced by servo-actuators. The servo-actuators and IBC control system were designed and manufactured by ZF Luftfahrttechnik GmbH. This control system allowed the pitch of each rotor blade to be changed independently of the other blades. The IBC inputs had large effects on the hub vibrations and BVI noise. However, the rotor hub moments were not retrimmed with each new IBC input. This resulted in an out-of-trim rotor configuration. The same IBC system was used in the second IBC test performed in 1994. This test more carefully investigated the potential of IBC to simultaneously reduce noise and vibration and also investigated the effect of IBC on rotor performance in high-speed-cruise flight. In the 1994 test, the hub moment and rotor thrust were readjusted to maintain rotor trim as the IBC inputs were applied. For this reason, the data taken from the second test are considered to be more accurate, except for some unique IBC input combinations not repeated in the second test. IBC controls that were evaluated were single-frequency inputs from 2/rev to 6/rev and multi-harmonic combinations of these frequencies to form pulses, wavelets, and doublets. Extensive data were acquired for each IBC data point. These data included rotor performance, average and time-varying hub loads, rotor blade bending loads, control system loads, inboard and outboard blade pitch motions, and BVI noise data. The rotor balance hub force and moment data included the mean values, half-peak-to-peak values, and sine/cosine harmonics up to the 20th rotor harmonic. The time history and averaged Fourier spectrum for each measurement are available electronically from NASA Ames Research Center. The data indicate that significant reduction in both BVI noise and hub vibration can be obtained using IBC. The 2/rev input produced the best single-frequency results. At a typical descent flight condition, 2/rev IBC combined with other IBC harmonics reduced the BVI noise up to 12 dB (85 percent) at some microphone locations. At the same time, this input could also reduce the dominant 4/rev vibratory hub loads by up to 75 percent. The data also show that performance improvements of up to 7 percent were obtained using 2/rev IBC at high-speed forward flight conditions. An analysis of the hydraulic power requirements for BVI noise suppression, vibration reduction, and rotor performance improvement is included in this report. This analysis shows that the power required by the IBC system is negligible at low-speed flight conditions, and that a net gain of 3 percent of rotor horsepower can be achieved at high-speed flight conditions.

Investigation↗

NASA NTRSDate not supplied

Buckling Testing of a Subscale Composite Cylinder

A subscale solid laminate composite cylinder with a 31.5-in. diameter, a 48.2-in. length, and a [23/0/-23]4S layup was designated NDL-1 and was designed to fail in buckling after a series of subcritical tests. NDL-1 was experimentally loaded in axial compression until buckling at 466.3 kips. Visual inspection of the test article after the test revealed that a shallow area of delamination occurred near the buckling initiation site. After a successful first buckling test, there was an opportunity to test NDL-1 in axial compression to failure a second time despite that the test article was not designed or analyzed for multiple buckling tests. During the second test to failure, NDL-1 reached a peak load of 390.4 kips, 16.3% lower than the first test. Buckling did not initiate in the same location during the second test to failure as the first test to failure. The second buckling event caused a large V-shaped crack that penetrated through the thickness of the barrel. Though buckling initiated at different locations, a similar radial deformation pattern was present just prior to buckling during the both tests. In the end, NDL-1 maintained a significant amount of its structural integrity and a similar prebuckling radial displacement pattern, even after the first buckling test.

Test↗

NASA NTRSDate not supplied

CFS Test Framework

NASA's Core Flight System (cFS) provides a generic flight software framework architecture for developing flight software. As the cFS framework has gained popularity over the years within the flight software community, supporting software tools have been developed to assist in the design, development, testing and verification of flight software. The cFS Test Framework (CTF) is a recently developed cFS tool with capabilities to develop and run automated test and verification scripts against flight software targets. The CTF tool parses and executes JSON-based test scripts containing test instructions, while logging and reporting the results. CTF utilizes a plugin-based architecture to allow developers to extend CTF with new test instructions, external interfaces, and custom functionality. To interface with flight software, CTF parses a set of CCSDS message definition files to create the necessary command and telemetry structures for use during the test run. Additionally, CTF also supports interfacing with multiple cFS instances, allowing a test script to verify requirements that involve multiple flight software targets. Lastly, CTF provides support for executing test scripts against FSW running on remote or embedded hardware. This allows CTF to execute the same test scripts across different target configurations throughout the development process. In this presentation, we will introduce the cFS Test Framework (CTF) architecture, discuss the history of cFS testing frameworks, and present the features and capabilities currently provided by CTF. Lastly, we will show a demo of the CTF tool being used to execute test scripts against flight software.

cfs↗

NASA NTRSDate not supplied

Icing Physics Studies Using the 3D SIDRM Test Article: Aerodynamic and Supercooled Liquid Icing Analysis

In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for development of icing physics models and simulation validation. To that end, this paper presents the analysis of the supercooled liquid icing data subset from tests conducted in 2022 at the NASA Icing Research Tunnel that studied both supercooled water and ice-crystal icing. The test article that was utilized replicated 3D geometrical features of an inter-compressor duct and strut region of a turbofan engine. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a scale to measure ice mass were utilized to characterize the icing behavior. The aim of these tests was to generate ice accretions on the SIDRM test article under well-characterized supercooled liquid icing and ice crystal icing conditions. This paper discusses measurements related to aerodynamic testing and supercooled liquid icing tests that were conducted. Aerodynamic measurements were analyzed and compared to computational simulations and were found to be in good agreement for the range of airspeeds (50 to 230 knots) and angles of attack (0 to 4°) tested. Various parametric sweeps were conducted during the supercooled liquid icing portion of the test entry (cloud median volumetric diameter ranged from 15 to 90 µm, total air temperature from -3 to -17 °C, angle of attack from 0 to 4°, and accretion time from 5 to 20 min). These sweeps were performed to measure that parameter’s impact on ice accretion size, location (icing extent), characteristics (such as glaze/rime ice and shedding behavior), and test article surface temperature. Analysis of the test data showed that clouds composed of larger drops, colder air temperatures, smaller angles of attack, and longer spray times were the primary parameters that resulted in accretions with greater ice mass. Test article angle of attack and cloud droplet size influenced the location of ice accretion as these two parameters directly impact collection efficiency. With respect to icing characteristics, total air temperature dictated icing type, and smaller cloud drop size along with warmer air temperatures resulted in greater amounts of ice shedding. Surface temperature increased during ice accretion from the release of latent (fusion) heat, where total air temperature and cloud drop size impacted the amount of surface temperature change. The icing measurements collected during the SIDRM tests will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost effective way.

supercooled liquid icing↗

NASA NTRSDate not supplied

Icing Physics Studies Using the 3D SIDRM Test Article: Ice Crystal Icing Analysis

In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for the development of icing physics models and simulation validation. This paper presents the analysis of the ice crystal icing data subset from tests conducted in 2022 at the NASA Icing Research Tunnel that studied both supercooled liquid and ice-crystal icing. The test article that was utilized replicated 3D geometrical features of an inter-compressor duct and strut region of a turbofan engine. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a weighing scale to measure ice mass were utilized to characterize the icing behavior. The aim of these tests was to generate ice accretions on the SIDRM test article under well-characterized icing conditions. To that end, ice crystal cloud characterization tests were conducted that provided cloud property values at the test section. The ice crystal accretion tests investigated how different test condition parameters impacted ice accretion size, location, and characteristics (such as physical attributes). A key finding was that a sufficiently high surface heat flux at the leading edge can provide a continuous supply of liquid melt to critical accretion zones downstream, resulting in elevated ice mass accretions. Another key finding was that warmer heater settings in critical accretion zones can suppress ice accretion. These findings are consistent with icing behavior observed in full-scale engine icing tests conducted previously at the NASA Glenn Research Center. Test runs investigating the contribution of liquid melt generated at the leading edge found that the melt can be transported downstream to critical accretion regions in two forms, via runback and splash. The form of melt supplied downstream affected accretion behavior and features. Sharkteeth-shaped ice accretions were generated at certain test conditions, a physical attribute that has been observed in full-scale engine icing tests. The ice accretion data will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost‑effective way.

ice crystal icing↗

NASA NTRSDate not supplied

Icing Physics Studies Using the 3D SIDRM Test Article: Ice Crystal Icing Analysis

In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for the development of icing physics models and simulation validation. This paper presents the analysis of the ice crystal icing data subset from tests conducted in 2022 at the NASA Icing Research Tunnel that studied both supercooled liquid and ice-crystal icing. The test article that was utilized replicated 3D geometrical features of an inter-compressor duct and strut region of a turbofan engine. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a weighing scale to measure ice mass were utilized to characterize the icing behavior. The aim of these tests was to generate ice accretions on the SIDRM test article under well-characterized icing conditions. To that end, ice crystal cloud characterization tests were conducted that provided cloud property values at the test section. The ice crystal accretion tests investigated how different test condition parameters impacted ice accretion size, location, and characteristics (such as physical attributes). A key finding was that a sufficiently high surface heat flux at the leading edge can provide a continuous supply of liquid melt to critical accretion zones downstream, resulting in elevated ice mass accretions. Another key finding was that warmer heater settings in critical accretion zones can suppress ice accretion. These findings are consistent with icing behavior observed in full-scale engine icing tests conducted previously at the NASA Glenn Research Center. Test runs investigating the contribution of liquid melt generated at the leading edge found that the melt can be transported downstream to critical accretion regions in two forms, via runback and splash. The form of melt supplied downstream affected accretion behavior and features. Sharkteeth-shaped ice accretions were generated at certain test conditions, a physical attribute that has been observed in full-scale engine icing tests. The ice accretion data will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost‑effective way.

ice crystal icing↗

DOE OSTI2022

Surveillance Test Articles Development

Material degradation in Advance Test Reactors (ATR) is governed by irradiation, corrosion, elevated temperature exposure and cyclic mechanical creep-fatigue loads. This degradation information during reactor operation condition is limited. Hence, material damage monitoring is a key aspect of the design, analysis and licensing of ATR components. The idea is to monitor material component operation conditions of component by using a surveillance test article. This test article is fabricated with bi-metal configuration with two different thermal expansion coefficients, and design is motivated by Simplified Model Test (SMT) specimen which can capture structure-like mechanical response. Upon raising temperature of the bi-metal test article configuration, expansion mismatch results tensile load on specimen. Thus, temperature dependent passively actuated loading is achieved. The idea is to place this surveillance test article in reactor at location ‘x’ to surveil the mechanical response at critical location ‘y’. By calibrating the test article design, material degradation at critical location can be surveilled through assessing the degradation in surveillance test article. This study presents test article development with different material combinations and follow-up experimental testing work through passively loading test article with temperature history. The test article geometry and observed test results are presented in presentation slides.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Structural Testing Technology Development: Cooperative Research and Development Final Report, CRADA Number CRD-06-00200

NREL is the only organization in the US that is accredited to conduct tests of wind turbine systems and components in accordance with International Electrotechnical Commission (IEC) test standards. The National Wind Technology Center houses the only full-scale wind turbine blade drivetrain test facilities in the US. To maintain these facilities, accreditation, and the acceptance of the wind industry, NREL must strive continuously to maintain and improve staff capabilities, procedures, facility and equipment. In addition, as wind turbines continue to increase in size, NREL must improve its capability to test the larger components associated with these new turbines. NREL is currently investigating methods to increase blade and drivetrain testing capabilities. Mitsubishi Power Systems (MPS) must also strive to meet the demands of the evolving wind energy industry by developing, proving and manufacturing new, cost-effective blades for its turbines. Mitsubishi has established a joint venture with TPI composites of Rhode Island for manufacturing blades to be installed on US wind turbines. There is an obvious advantage to test these prototype blades in a US facility. The NREL blade test facility is uniquely capable of fulfilling this need. In addition, NREL can provide other testing support to MPS through the use of its dynamometer facility for drivetrain testing and through the use of NREL’s field-testing capabilities for testing wind turbine systems. This CRADA provides the opportunity for both organizations to achieve critical goals in development of wind energy in the US. MPS obtains verification of its wind turbine components and system. NREL obtains improved test capabilities.

17 WIND ENERGY↗

DOE OSTI2024

Characteristics of a cost-effective blood test for colorectal cancer screening

Background: Blood-based biomarker tests can potentially change the landscape of colorectal cancer (CRC) screening. We characterize the conditions under which blood test screening would be as effective and cost-effective as annual fecal immunochemical testing or decennial colonoscopy. Methods: We used the 3 Cancer Information and Surveillance Modeling Network–Colon models to compare scenarios of no screening, annual fecal immunochemical testing, decennial colonoscopy, and a blood test meeting Centers for Medicare & Medicaid (CMS) coverage criteria (74% CRC sensitivity and 90% specificity). We varied the sensitivity to detect CRC (74%-92%), advanced adenomas (10%-50%), screening interval (1-3 years), and test cost ($25-$500). Primary outcomes included quality-adjusted life-years (QALY) gained from screening and costs for a US average-risk cohort of individuals aged 45 years. Results: Annual fecal immunochemical testing yielded 125-163 QALY gained per 1000 at a cost of 3811-5384 dollars per person, whereas colonoscopy yielded 132-177 QALY gained at a cost of 5375-7031 dollars per person. A blood test with 92% CRC sensitivity and 50% advanced adenoma sensitivity yielded 117-162 QALY gained if used every 3 years and 133-173 QALY gained if used every year but would not be cost-effective if priced above $$125 per test. If used every 3 years, a $500 blood test only meeting CMS coverage criteria yielded 83-116 QALY gained at a cost of $8559-$9413 per person. Conclusion: Blood tests that only meet CMS coverage requirements should not be recommended to patients who would otherwise undergo screening by colonoscopy or fecal immunochemical testing because of lower benefit. Blood tests need higher advanced adenoma sensitivity (above 40%) and lower costs (below $125) to be cost-effective.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

Project Plan: Salt in Situ Heater Test

This project plan gives a high-level description of the US Department of Energy Office of Nuclear Energy (DOE-NE) Spent Fuel and Waste Disposition (SFWD) campaign in situ borehole heater test project planned for the Waste Isolation Pilot Plant (WIPP) site, titled the Brine Availability Test in Salt (BATS). BATS is the first stage in a planned sequence of tests to bolster the technical basis for disposal of heat generating waste in salt. This plan provides an overview of the schedule and responsibilities of the parties involved. This project is a collaborative effort by Sandia, Los Alamos, and Lawrence Berkeley National Laboratories to execute a series of small-diameter borehole heater tests in salt for the DOE-NE SFWD campaign. Design of a heater test in salt at WIPP has evolved over several years. The experiment has begun in January 2020 and the first phase will continue for several months with the possibility for follow on testing. BATS comprises a suite of modular tests, which consist of a group of adjacent horizontal boreholes in the wall of drifts at WIPP. Each test is centered around a packer-isolated heated borehole (12.2 cm [4.81 diameter) containing equipment for water-vapor collection and borehole closure monitoring, surrounded by smaller-diameter (up to 5.3 cm [2.11 diameter) satellite observation boreholes. Observation boreholes contain grouted-in temperature sensors, electrical resistivity tomography (ERT) sensors, and fiber optics; packer-isolated tracer release and sampling intervals; and acoustic emission (AE) piezoelectric sensors. A larger-diameter (12.2 cm [4.81) satellite borehole includes sorel and salt cement plugs, as part of an engineered barrier sealing test. The first two tests, to be implemented in parallel, are heated (target borehole wall temperature of 120 °C) and unheated, with similar arrays of observation borehole monitoring changes. Follow-on tests will be designed using information gathered from the first two tests, and may be conducted at other borehole wall temperatures, use multiple observation boreholes, and may include different measurement types and test designs. This 2020 update of the original 2018 project plan satisfies DOE-NE Spent Fuel and Waste Science and Technology (SFWST) milestone M3SF-205N010303034, as part of the SNL "Salt Disposal R&D" work package.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Pressurizing Hagan and SAVY containers to 30-psig (air) to measure the release of analytical cerium oxide test powder

In response to an ESS surrounding the storage of sealed sources at TA-55, personnel from RP-SVS (Radiation Protection Services) and ORI-2 (Operational Readiness & Execution) were approached by ES-55 (Facility System Engineering) to provide technical testing of known nuclear material storage containers. Testing criteria were determined by SB-PF (Safety Basis for Plutonium Facilities). Tests were conducted in conjunction with multiple related projects at the Aerosol Sciences Laboratory (TA-03-0130-0103). An experimental system was quickly developed to deliver a pressure pulse (30-psig) that mimics a sealed source burst scenario. A series of twelve tests was conducted. Six tests were done with two different 5QT SAVY-4000 containers, where each SAVY filter-lid combination was subjected to three successive test insults. Three tests were done with a (0.375" diameter filter) 8Q.T Hagan container, and three tests with a (0.625" diameter filter) 8QT Hagan container. An unused, fresh container filter was used for each tested Hagan container, each receiving only one test insult per filter. Cerium oxide (CeO 2 ) powder was loaded (100 grams per test) into a nozzle in the tested Hagan and SAVY containers, and the nozzle was hard-plumbed to a ball valve and a pressure source. This system was installed into the Los Alamos RRFMC (Respirable Release Measurement Chamber), which is an integrated multipurpose aerosol wind tunnel that satisfies NQA-1 subpart 2.4 for R&D work. The ball valve was fitted with a mechanical linkage for operation from outside the wind tunnel. An aerodynamic particle sizer counted the particle concentrations and size distributions of released aerosol. Respirable aerosol released during the tests was measured and a correction factor for wind tunnel flowrate and internal duct deposition was applied.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Radiometric Testing of Germicidal UV Products, Round 1: UV-C Towers and Whole-Room Luminaires (CALiPER Full Report)

This report analyzes the independently tested performance of 13 germicidal ultraviolet (GUV) products purchased between February and July 2022. The products were of three different types: • Seven portable, consumer-oriented GUV towers designed to be placed on the floor or a desk of an unoccupied room to disinfect air and surfaces. Five of these products used LED sources and two products had low-pressure mercury (LPM) sources. • One GUV whole-room luminaire designed to be installed on a ceiling to disinfect air when a room is occupied. This product had LED sources. • Five GUV troffer or high-bay style whole-room luminaires designed to be installed in or suspended from a ceiling to disinfect air and surfaces when a room is unoccupied. All five had LPM sources. Product testing covered radiometric and electrical performance for all 13 products as well as photobiological safety evaluation if product documentation included testable claims. Measurement results enable comparison between products and against manufacturer or vendor claims. Testing identified numerous issues related to the accuracy of claimed GUV product performance. Claims were often untestable, contradictory, ambiguous, or used incorrect units and/or terminology. When claims were testable, they often did not match test results. For example, three LED products that claimed to emit UV-C emitted only UV-A. Product claim issues were more common among consumer-oriented tower products, but all product types exhibited problems with accurate performance claims. The UV-C radiant efficiency (calculated as UV-C output power divided by electrical input power) of the products varied widely, even among similar products using the same source technologies. For example, the UV-C radiant efficiency of LPM products varied by greater than a factor of three for the same product type, indicating a large potential energy savings opportunity for products that are better designed for efficiency. LED products had orders-of-magnitude lower UV-C radiant efficiency than LPM products. This study also identified several testing challenges and limitations. Most significant among these is the capability to accurately test and report the performance of larger GUV products. Whereas integrating spheres are used to quickly measure total radiant flux (i.e., output power) and spectral distribution, goniometers are used to measure radiant intensity distribution (from which radiant flux can be calculated). Integrating spheres require a specialized and costly coating to test UV, and the testing laboratory for this round of products had only a 20-inch diameter hemisphere with this capability. The integrating sphere accommodated just 2 of the 10 UV-C emitting products. Goniometer testing had a different size limitation in that mirrors typically used to increase goniometer test distance to the far field reflect little to no UV. As a result, the study evaluated only 6 of 13 products in the far field. Electronic files of UV-C intensity data for the other 7 products, which would typically be imported into design software for designing GUV applications, may not be reliable for predicting irradiance at arbitrary far-field distances (IES 2022a; CIE 2020). Specifiers and buyers of GUV products need accurate performance claims and data to deploy GUV technology safely and effectively. This CALiPER GUV Round 1 report demonstrates the significant education and training manufacturers and vendors still require to accurately test and report the performance of their GUV products. Further industry standards and guidelines may address testing limitations and improve test methods, product performance, and the accuracy of performance claims.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Performance Testing of a Moving Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Hydraulic Testing of the Lost Lake Aquifer Near Recovery Well RWM001R

An aquifer pumping test was conducted on the Lost Lake Aquifer Zone (LLAZ) at the recently installed recovery well RWM001R in accordance with the approved test plan (Dixon, 2024). The objective of the testing was to determine baseline well performance parameters and aquifer hydraulic conductivity. This testing consisted of two step-drawdown tests to determine well performance properties and two constant pumping rate aquifer tests with recovery periods to determine aquifer hydraulic properties. Well performance parameters determined included specific capacity, well efficiency, and head loss coefficients. The results of the step-drawdown testing are presented in Tables ES1 and ES2 whereas the results of the constant pumping rate testing are presented in Table ES3. The average specific capacity of RWM001R operating at pump capacity (~54 gpm) was 2.2 gpm/ft using data from the final step of both tests. The average well efficiency determined from both step-drawdown tests was 56% using data from the final step of both tests. For both step-drawdown tests, well efficiency was inversely related to the pumping rate with the average efficiency decreasing from approximately 79% to 56%. Aquifer head loss coefficients from both tests were comparable (Table ES2).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Modeling and Analysis for Spent Nuclear Fuel Seismic Testing

Note: This is the final public release version of PNNL-31671 Draft, which was previously released to the sponsor for review. The intent is the public release version will be PNNL-31671. There are no significant changes from the earlier draft version. This unlimited distribution report is the deliverable for M3SF-21PN010202014: Modeling and Analysis for Spent Nuclear Fuel Seismic Testing. This report summarizes the modeling, analysis, and test plan support completed by Pacific Northwest National Laboratory for the spent nuclear fuel dry storage system seismic test plan through May of 2021. Test plan preparation is planned to continue until the seismic test is completed in July of 2022. This report covers preliminary structural dynamic model development and computer-aided design of test hardware. Based on preliminary modeling, the strongest earthquakes under consideration in this test program provide mechanical loading on the spent nuclear fuel that is comparable to the 30 cm cask drop scenario, although the loads do not appear to be strong enough to cause significant permanent deformation of the fuel assembly spacer grids. The potential for grid deformation during the test will be assessed when the proposed shake table motion becomes available. The weakest earthquakes considered in this test are expected to be comparable to the mechanical loads witnessed in the multimodal transportation test of 2017. The horizontal canister system is predicted to provide nearly-uniform loading condition on the fuel assemblies it contains, while the vertical cask system is predicted to cause non-uniform dynamic loads on the fuel assemblies. In the horizontal case, gravity keeps the fuel assemblies in contact with one basket wall surface unless the loads are strong enough to cause a separation. In the vertical case, the fuel assemblies are relatively long and slender, and seismic motion in the anticipated test range is predicted to cause the assemblies to lean, tilt, and impact the basket walls throughout the seismic event. These gap closures are a nonlinear force transmission condition, so the vertical system is expected to have more variation and variability than the horizontal system. While the horizontal system is expected to have a relatively more linear response than the vertical system, there is still the potential for nonlinear behavior in the horizontal system because the fuel assemblies are free to slide, bounce, and impact the basket walls if the seismic loads are strong enough. One major conclusion of this study is that the use of mixed fuel assemblies in the canister will be acceptable. There are differences in overall system response when the mass, center of gravity, or gaps are changed, but the changes in response are within the bounds of a system that contains completely homogeneous fuel assemblies. One important observation is that the loading for each individual fuel assembly within the vertical canister is expected to be different from that of the others because of nonlinearities in the system. The horizontal canister system is expected to have a more uniform and more predictable response than the vertical canister, making variations in fuel assembly characteristics easier to account for. One important recommendation that comes from this modeling work is to repeat some of the strongest shake tests at different angles, particularly for the vertical cask system. Modeling predicts that strong seismic motion will cause the fuel assemblies to close initial gaps and impact the fuel basket walls when the canister is in the vertical cask configuration. Each shake test will impose a pre-defined three-dimensional time history on the cask system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1985

Integrated Application of Active Controls (IAAC) technology to an advanced subsonic transport project: Test act system validation

The primary objective of the Test Active Control Technology (ACT) System laboratory tests was to verify and validate the system concept, hardware, and software. The initial lab tests were open loop hardware tests of the Test ACT System as designed and built. During the course of the testing, minor problems were uncovered and corrected. Major software tests were run. The initial software testing was also open loop. These tests examined pitch control laws, wing load alleviation, signal selection/fault detection (SSFD), and output management. The Test ACT System was modified to interface with the direct drive valve (DDV) modules. The initial testing identified problem areas with DDV nonlinearities, valve friction induced limit cycling, DDV control loop instability, and channel command mismatch. The other DDV issue investigated was the ability to detect and isolate failures. Some simple schemes for failure detection were tested but were not completely satisfactory. The Test ACT System architecture continues to appear promising for ACT/FBW applications in systems that must be immune to worst case generic digital faults, and be able to tolerate two sequential nongeneric faults with no reduction in performance. The challenge in such an implementation would be to keep the analog element sufficiently simple to achieve the necessary reliability.

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