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NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design. This advanced PLSS is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data, define set-points, evaluate control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out in 2013 and 2014 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Anchondo, Ian↗

NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Human-in-the-Loop (HITL) Testing

The space suit Portable Life Support System (PLSS) 2.0 represents the second integrated prototype developed and tested to mature a design that uses advanced technologies to reduce consumables, improve robustness, and provide additional capabilities over the current state of the art. PLSS 2.0 was developed in 2012, with extensive functional evaluations and system performance testing through mid-2014. In late 2014, PLSS 2.0 was integrated with the Mark III space suit in an ambient laboratory environment to facilitate manned testing, designated PLSS 2.0 Human-in-the-Loop (HITL) testing, in which the PLSS prototype performed the primary life support functions, including suit pressure regulation, ventilation, carbon dioxide control, and cooling of the test subject and PLSS avionics. The intent of this testing was to obtain subjective test subject feedback regarding qualitative aspects of PLSS 2.0 performance such as thermal comfort, sounds, smells, and suit pressure fluctuations due to the cycling carbon dioxide removal system, as well as to collect PLSS performance data over a range of human metabolic rates from 500-3000 Btu/hr. Between October 27 and December 18, 2014, nineteen two-hour simulated EVA test points were conducted in which suited test subjects walked on a treadmill to achieve a target metabolic rate. Six test subjects simulated nominal and emergency EVA conditions with varied test parameters including metabolic rate profile, carbon dioxide removal control mode, cooling water temperature, and Liquid Cooling and Ventilation Garment (state of the art or prototype). The nineteen test points achieved more than 60 hours of test time, with 36 hours accounting for simulated EVA time. The PLSS 2.0 test article performed nominally throughout the test series, confirming design intentions for the advanced PLSS. Test subjects' subjective feedback provided valuable insight into thermal comfort and perceptions of suit pressure fluctuations that will influence future advanced PLSS design and testing strategies.

Watts, Carly↗

DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Aquifer Hydraulic Testing and Characterization Plan for the Ringold Formation Unit A in the Hanford 200-ZP-1 Groundwater Operable Unit and Vicinity

This document presents a plan for testing and characterizing the hydraulic properties of the Ringold Formation, member of Wooded Island – unit A (Rwia) in the 200-ZP groundwater operable unit. The testing approach includes multiple field methods and associated analyses designed to investigate and understand aquifer hydraulic properties over a range of scales. Testing was designed to achieve specific testing objectives identified previously in the 200 ZP-1 Groundwater Operable Unit Ringold Formation Unit A Characterization Sampling and Analysis Plan (Ringold A SAP). The test plan provides necessary technical and operational detail for writing subsequent field test instruction documents specific to each testing location. Hydraulic characterization activities will proceed in a phased manner focusing on areas identified to have knowledge gaps and also critical for remedy modifications and/or selection. These activities are designed to minimize impact to pump-and-treat (P&T) operations and to use existing P&T injection and extraction wells as stress wells, and include use of the new Rwia monitoring wells installed for Ringold A SAP activities. ZP-1 hydraulic testing will include slug testing in new Rwia wells, shutdown-recovery tests in multiple Rwia and composite Ringold Formation member of Wooded Island – unit E (Rwie)-Rwia aquifer test locations, installation of new Automated Water Level Network stations in Rwia monitoring wells, characterization of P&T and barometric responses, identifying the vertical distribution of hydraulic conductivity in the Rwia and Rwie units using electromagnetic borehole flowmeter tests, and single-well tracer testing in select Rwia monitoring wells. Slug testing to be conducted during drilling is described under the Ringold A SAP. The remaining testing activities are to be conducted after well drilling and completion and are described in this test plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Generic characterization of electrical test benches for AC- and HVDC-connected wind power plants

The electrical test and assessment of wind turbines go hand in hand with standards and network connection requirements. In this paper, the generic structure of advanced electrical test benches, including grid emulator or controllable grid interface, wind torque emulator, and device under test, is proposed to harmonize state-of-the-art test sites. On the other hand, modern wind turbines are under development towards new features, concerning grid-forming, black-start, and frequency support capabilities as well as harmonic stability and control interaction considerations, to secure the robustness and stability of renewable-energy-based power systems. Therefore, it is necessary to develop new and revised test standards and methodologies to address the new features of wind turbines. This paper proposes a generic test structure within two main groups, including open-loop and closed-loop tests. The open-loop tests include the IEC 61400-21-1 standard tests as well as the additional proposed test options for the new capabilities of wind turbines, which replicate grid connection compliance tests using open-loop references for the grid emulator. In addition, the closed-loop tests evaluate the device under test as part of a virtual wind power plant and perform real-time simulations considering the grid dynamics. The closed-loop tests concern grid connection topologies consisting of AC and HVDC, as well as different electrical characteristics, including impedance, short-circuit ratio, inertia, and background harmonics. The proposed tests can be implemented using available advanced test benches by adjusting their control systems. The characteristics of a real power system can be emulated by a grid emulator coupled with real-time digital simulator systems through a high-bandwidth power-hardware-in-the-loop interface.

17 WIND ENERGY↗

NASA NTRS2005

Force Limited Vibration Testing

This slide presentation reviews the concept and applications of Force Limited Vibration Testing. The goal of vibration testing of aerospace hardware is to identify problems that would result in flight failures. The commonly used aerospace vibration tests uses artificially high shaker forces and responses at the resonance frequencies of the test item. It has become common to limit the acceleration responses in the test to those predicted for the flight. This requires an analysis of the acceleration response, and requires placing accelerometers on the test item. With the advent of piezoelectric gages it has become possible to improve vibration testing. The basic equations have are reviewed. Force limits are analogous and complementary to the acceleration specifications used in conventional vibration testing. Just as the acceleration specification is the frequency spectrum envelope of the in-flight acceleration at the interface between the test item and flight mounting structure, the force limit is the envelope of the in-flight force at the interface . In force limited vibration tests, both the acceleration and force specifications are needed, and the force specification is generally based on and proportional to the acceleration specification. Therefore, force limiting does not compensate for errors in the development of the acceleration specification, e.g., too much conservatism or the lack thereof. These errors will carry over into the force specification. Since in-flight vibratory force data are scarce, force limits are often derived from coupled system analyses and impedance information obtained from measurements or finite element models (FEM). Fortunately, data on the interface forces between systems and components are now available from system acoustic and vibration tests of development test models and from a few flight experiments. Semi-empirical methods of predicting force limits are currently being developed on the basis of the limited flight and system test data. A simple two degree of freedom system is shown and the governing equations for basic force limiting results for this system are reviewed. The design and results of the shuttle vibration forces (SVF) experiments are reviewed. The Advanced Composition Explorer (ACE) also was used to validate force limiting. Test instrumentation and supporting equipment are reviewed including piezo-electric force transducers, signal processing and conditioning systems, test fixtures, and vibration controller systems. Several examples of force limited vibration testing are presented with some results.

random vibration testing↗

NASA NTRS2016

Successful Completion of the JWST OGSE2 Cryogenic Test at JSC Chamber-A While Managing Numerous Challenges

The James Webb Space Telescope (JWST) Optical Telescope Element (OTE) assembly is the largest optically stable infrared-optimized telescope currently being manufactured and assembled, and scheduled for launch in 2018. The JWST OTE, including the primary mirrors, secondary mirror, and the Aft Optics Subsystems (AOS) are designed to be passively cooled and operate at near 45 degrees Kelvin. Due to the size of its large sunshield in relation to existing test facilities, JWST cannot be optically or thermally tested as a complete observatory-level system at flight temperatures. As a result, the telescope portion along with its instrument complement will be tested as a single unit very late in the program, and on the program schedule critical path. To mitigate schedule risks, a set of 'pathfinder' cryogenic tests will be performed to reduce program risks by demonstrating the optical testing capabilities of the facility, characterizing telescope thermal performance, and allowing project personnel to learn valuable testing lessons off-line. This paper describes the 'pathfinder' cryogenic test program, focusing on the recently completed second test in the series called the Optical Ground Support Equipment 2 (OGSE2) test. The JWST OGSE2 was successfully completed within the allocated project schedule while faced with numerous conflicting thermal requirements during cool-down to the final cryogenic operational temperatures, and during warm-up after the cryo-stable optical tests. The challenges include developing a pre-test cool-down and warm-up profiles without a reliable method to predict the thermal behaviors in a rarified helium environment, and managing the test article hardware safety driven by the project Limits and Constraints (L&C's). Furthermore, OGSE2 test included the time critical Aft Optics Subsystem (AOS), a part of the flight Optical Telescope Element that would need to be placed back in the overall telescope assembly integrations. The OGSE2 test requirements included the strict adherence of the project contamination controls due to the presence of the contamination sensitive flight optical elements. The test operations required close coordination of numerous personnel while they being exposed and trained for the 'final' combined OTE and instrument cryo-test in 2017. This paper will also encompass the OGSE2 thermal data look-back review.

JWST OGSE2 Cryogenic Test↗

DOE OSTI2015

Response Time Analysis and Test of Protection System Instrument Channels for APR1400 and OPR1000

Safety limits are required to maintain the integrity of physical barriers designed to prevent the uncontrolled release of radioactive materials in nuclear power plants. The safety analysis establishes two critical constraints that include an analytical limit in terms of a measured or calculated variable, and a specific time after the analytical limit is reached to begin protective action. Keeping with the nuclear regulations and industry standards, satisfying these two requirements will ensure that the safety limit will not be exceeded during the design basis event, either an anticipated operational occurrence or a postulated accident. Various studies on the setpoint determination methodology for the safety-related instrumentation have been actively performed to ensure that the requirement of the analytical limit is satisfied. In particular, the protection setpoint methodology for the advanced power reactor 1400 (APP1400) and the optimized power reactor 1000 (OPR1000) has been recently developed to cover both the design basis event and the beyond design basis event. The developed setpoint methodology has also been quantitatively validated using specific computer programs and setpoint calculations. However, the safety of nuclear power plants cannot be fully guaranteed by satisfying the requirement of the analytical limit. In spite of the response time verification requirements of nuclear regulations and industry standards, it is hard to find the studies on the systematically integrated methodology regarding the response time evaluation. In cases of APR1400 and OPR1000, the response time analysis for the plant protection system is partially included in the setpoint calculation and the response time test is separately performed via the specific plant procedure. The test technique has a drawback which is the difficulty to demonstrate completeness of timing test. The analysis technique has also a demerit of resulting in extreme times that not actually possible. Thus, the establishment of the systematic response time evaluation methodology is needed to justify the conformance to the response time requirement used in the safety analysis. This paper proposes the response time evaluation methodology for APR1400 and OPR1000 using the combined analysis and test technique to confirm that the plant protection system can meet the analytical response time assumed in the safety analysis. In addition, the results of the quantitative evaluation performed for APR1400 and OPR1000 are presented in this paper. The proposed response time analysis technique consists of defining the response time requirement, determining the critical signal path for the trip parameter, allocating individual response time to each component on the signal path, and analyzing the total response time for the trip parameter, and demonstrates that the total analyzed response time does not exceed the response time requirement. The proposed response time test technique is composed of defining the response time requirement, determining the critical signal path for the trip parameter, determining the test method for each component on the signal path, performing the response time test, and demonstrates that the total test result does not exceed the response time requirement. The total response time should be tested in a single test that covers from the sensor to the final actuation device on the instrument channel. When the total channel is not tested in a single test, separate tests on groups of components or single components including the total instrument channel shall be combined to verify the total channel response. For APR1400 and OPR1000, the ramp test technique is used for the pressure and differential pressure transmitters and the step function testing technique is applied to the signal processing equipment and final actuation device. As a result, it can be demonstrated that the response time requirement is satisfied by the combined analysis and test technique. Therefore, the proposed methodology in this paper plays a crucial role in guaranteeing the safety of the nuclear power plants systematically satisfying one of two critical requirements from the safety analysis. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Fuel cladding post-quench LOCA embrittlement: mechanical test relevance

During a loss-of-coolant-accident (LOCA), the fuel cladding is submitted to a high temperature increase in a steam environment, along with an internal pressure increase which would eventually lead to ballooning and burst of the cladding. Steam could then penetrate through the burst opening and lead to inner surface oxidation and secondary-hydriding of the cladding. Post-quench cladding rupture can then occur either in two-sided oxidized area with wall thinning due to ballooning, or in single-sided oxidized area with large hydrogen content. Common tests involved in the evaluation of the post-quench ductility are Ring Compression Tests (RCT), Expansion Due to Compression Test (EDC) or Axial Tensile Tests (AT). Questions arise about these mechanical tests, as for instance, the influence on sample failure of the oxide layer thickness partitioning between inner and outer diameter. A systematic study was carried out to compare several mechanical tests on both single-sided and two-sided Zircaloy-4 oxidized samples. Five different mechanical tests were compared, including RCT: C-shaped ring Compression Test (CCT), Axial Tensile test (AT), Ring Tensile Test with well-defined machined gage section (RTT) and plain Ring Tensile Test (pRTT). All samples were taken from cladding tubes which had been oxidized in steam at 1200 Celsius degrees and then water-quenched. Mechanical tests were performed at room temperature and two to three samples were tested for each oxidation conditions and for every sample geometry to assess the reproducibility. Metallographic examinations were carried out to measure the ZrO{sub 2} and αZr(O) layer thicknesses and the ex-β/α(O) phase fraction. Mean hydrogen content measurements were also performed systematically on each sample. Results indicate that the different mechanical tests have not the same sensitivity to the oxide layer partitioning: RTT and pRTT load at failure seems to depend mainly on the cumulated oxide layer thickness rather than on its partitioning, whereas this parameter has an impact on CCT and AT test results. For all tensile tests, stresses at failure were derived from load-displacement curves. The failure of brittle samples was assumed to be governed by linear elastic fracture mechanics. Using conventional stress intensity factor solution, a value of the material fracture toughness controlling the sample failure was determined from experimental results and discussed. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

Results from Two Full-Scale Hawker 4000 Fuselage Drop Tests

In the spring of 2022, NASA Langley Research Center (LaRC) conducted two full-scale drop tests on a Hawker 4000 partial fuselage structure for the evaluation of composite material response under dynamic impact loading conditions. The specific objectives of the tests were to induce dynamic composite damage initiation and progression and in primary structure and to understand the nature of the failure modes. The tests were conducted via dividing the fuselage hardware into three smaller sections. Dynamic drop tests were conducted on the forward and aft portions of the fuselage under different dynamic loading conditions, while the middle section was reserved for materials testing. Both tests were conducted by dropping the test articles from a height of 14 feet with significant amounts of pitch, which was added to initiate damage in specific regions of the structure. The test articles were ballasted then instrumented with accelerometers at various locations and speckle-coated on both exterior sides with a black and white stochastic pattern for use with three-dimensional digital image correlation (3D-DIC). In addition, the interior belly portion of the forward section test article was also speckle-coated, which was intended to capture deformations on the belly of the test article from the interior at impact. The interior of the aft section test article was not speckle-coated. Prior to testing, bow-tie markers were applied at various locations for use in marker tracking, to measure impact conditions such as vertical impact velocity and pitch. In this report, a partial summary of the data collected from the tests is presented. The data was primarily in the form of accelerometers to measure impact acceleration and 3D-DIC to measure deformation and failure onset and propagation. Post-test inspections revealed the primary damage mechanism was fiber cracking and delamination primarily in and around the area that contacted the impact surface. Acceleration pulse shapesin the ballast locations were trapezoidal in nature and ranged between 10 g and 40 g, depending on the location and test.

full scale testing↗

NASA NTRSDate not supplied

Results from Two Full-Scale Hawker 4000 Fuselage Drop Tests

full scale testing↗

DOE OSTI2016

SU-G-TeP4-15: The Roucoulette: A Set of Quality Control Tests for Dynamic Trajectory (4Pi) Treatment Delivery Techniques

Purpose: To present and validate a set of quality control tests for trajectory treatment delivery using synchronized dynamic couch (translation and rotation), MLC and collimator motion. Methods: The quality control tests are based on the Picket fence test, which consist of 5 narrow band 2mm width spaced at 2.5cm intervals, and adds progressively synchronized dynamic motions. The tests were exposed on GafChromic EBT3 films. The first test is a regular (no motion and MLC static while beam is on) Picket Fence test used as baseline. The second test includes simultaneous collimator and couch rotation, each stripe corresponding to a different rotation speed. Errors in these tests were introduced (0.5 degree and 1 degree error in rotation synchronization) to assess the error sensitivity of this test. The second test is similar to the regular Picket Fence but now including dynamic MLC motion and couch translation (including acceleration during delivery) while the beam is on. Finally in the third test, which is a combination of the first and second test, the Picket Fence pattern is delivered using synchronized collimator and couch rotation and synchronized dynamic MLC and couch translation including acceleration. Films were analyzed with FilmQA Pro. Results: The distance between the peaks in the dose profile where measured (18.5cm away from the isocentre in the inplane direction where non synchronized rotation would have the largest effect) and compared to the regular Picket Fence tests. For well synchronized motions distances between peaks where between 24.9–25.4 mm identical to the regular Picket Fence test. This range increased to 24.4–26.4mm and 23.4–26.4mm for 0.5 degree and 1 degree error respectively. The amplitude also decreased up to 15% when errors are introduced. Conclusion: We demonstrated that the Roucoulette tests can be used as a quality control tests for trajectory treatment delivery using synchronized dynamic motion.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2013

Closure Report for Corrective Action Unit 104: Area 7 Yucca Flat Atmospheric Test Sites, Nevada National Security Site, Nevada

This Closure Report (CR) presents information supporting closure of Corrective Action Unit (CAU) 104, Area 7 Yucca Flat Atmospheric Test Sites, and provides documentation supporting the completed corrective actions and confirmation that closure objectives for CAU 104 were met. This CR complies with the requirements of the Federal Facility Agreement and Consent Order (FFACO) that was agreed to by the State of Nevada; the U.S. Department of Energy (DOE), Environmental Management; the U.S. Department of Defense; and DOE, Legacy Management. CAU 104 consists of the following 15 Corrective Action Sites (CASs), located in Area 7 of the Nevada National Security Site: · CAS 07-23-03, Atmospheric Test Site T-7C · CAS 07-23-04, Atmospheric Test Site T7-1 · CAS 07-23-05, Atmospheric Test Site · CAS 07-23-06, Atmospheric Test Site T7-5a · CAS 07-23-07, Atmospheric Test Site - Dog (T-S) · CAS 07-23-08, Atmospheric Test Site - Baker (T-S) · CAS 07-23-09, Atmospheric Test Site - Charlie (T-S) · CAS 07-23-10, Atmospheric Test Site - Dixie · CAS 07-23-11, Atmospheric Test Site - Dixie · CAS 07-23-12, Atmospheric Test Site - Charlie (Bus) · CAS 07-23-13, Atmospheric Test Site - Baker (Buster) · CAS 07-23-14, Atmospheric Test Site - Ruth · CAS 07-23-15, Atmospheric Test Site T7-4 · CAS 07-23-16, Atmospheric Test Site B7-b · CAS 07-23-17, Atmospheric Test Site - Climax Closure activities began in October 2012 and were completed in April 2013. Activities were conducted according to the Corrective Action Decision Document/Corrective Action Plan for CAU 104. The corrective actions included No Further Action and Clean Closure. Closure activities generated sanitary waste, mixed waste, and recyclable material. Some wastes exceeded land disposal limits and required treatment prior to disposal. Other wastes met land disposal restrictions and were disposed in appropriate onsite landfills. The U.S. Department of Energy, National Nuclear Security Administration Nevada Field Office (NNSA/NFO) requests the following: · A Notice of Completion from the Nevada Division of Environmental Protection to NNSA/NFO for closure of CAU 104 · The transfer of CAU 104 from Appendix III to Appendix IV, Closed Corrective Action Units, of the FFACO

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Laboratory Evaporation Testing Of Hanford Waste Treatment Plant Low Activity Waste Off-Gas Condensate Simulant

The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream, LAW Off-Gas Condensate, from the off-gas system. The baseline plan for disposition of this stream is to send it to the WTP Pretreatment Facility, where it will be blended with LAW, concentrated by evaporation and recycled to the LAW vitrification facility again. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable de-coupled operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of canistered glass waste forms. This LAW Off-Gas Condensate stream contains components that are volatile at melter temperatures and are problematic for the glass waste form. Because this stream recycles within WTP, these components accumulate in the Condensate stream, exacerbating their impact on the number of LAW glass containers that must be produced. Approximately 32% of the sodium in Supplemental LAW comes from glass formers used to make the extra glass to dilute the halides to be within acceptable concentration ranges in the LAW glass. Diverting the stream reduces the halides in the recycled Condensate and is a key outcome of this work. Additionally, under possible scenarios where the LAW vitrification facility commences operation prior to the WTP Pretreatment facility, identifying a disposition path becomes vitally important. This task examines the impact of potential future disposition of this stream in the Hanford tank farms, and investigates auxiliary evaporation to enable another disposition path. Unless an auxiliary evaporator is used, returning the stream to the tank farms would require evaporation in the 242-A evaporator. This stream is expected to be unusual because it will be very high in corrosive species that are volatile in the melter (chloride, fluoride, sulfur), will have high ammonia, and will contain carryover particulates of glass-former chemicals. These species have potential to cause corrosion of tanks and equipment, precipitation of solids, release of ammonia gas vapors, and scale in the tank farm evaporator. Routing this stream to the tank farms does not permanently divert it from recycling into the WTP, only temporarily stores it prior to reprocessing. Testing is normally performed to demonstrate acceptable conditions and limits for these compounds in wastes sent to the tank farms. The primary parameter of this phase of the test program was measuring the formation of solids during evaporation in order to assess the compatibility of the stream with the evaporator and transfer and storage equipment. The origin of this LAW Off-Gas Condensate stream will be the liquids from the Submerged Bed Scrubber (SBS) and the Wet Electrostatic Precipitator (WESP) from the LAW facility melter offgas system. The stream is expected to be a dilute salt solution with near neutral pH, and will likely contain some insoluble solids from melter carryover. The soluble components are expected to be mostly sodium and ammonium salts of nitrate, chloride, and fluoride. This stream has not been generated yet, and, thus, the composition will not be available until the WTP begins operation, but a simulant has been produced based on models, calculations, and comparison with pilot-scale tests. This report discusses results of evaporation testing of the simulant. Two conditions were tested, one with the simulant at near neutral pH, and a second at alkaline pH. The neutral pH test is comparable to the conditions in the Hanford Effluent Treatment Facility (ETF) evaporator, although that evaporator operates at near atmospheric pressure and tests were done under vacuum. For the alkaline test, the target pH was based on the tank farm corrosion control program requirements, and the test protocol and equipment was comparable to that used for routine evaluation of feed compatibility studies for the 242-A evaporator. One of the radionuclides that is volatile in the melter and expected to be in high concentration in this LAW Off-Gas Condensate stream is Technetium-99 (99Tc). Technetium will not be removed from the aqueous waste in the Hanford WTP, and will primarily end up immobilized in the LAW glass by repeated recycle of the off-gas condensate into the LAW melter. Other radionuclides that are also expected to be in appreciable concentrations in the LAW Off-Gas Condensate are 129I, 90Sr, 137Cs, and 241Am. The concentrations of these radionuclides in this stream will be much lower than in the LAW, but they will still be higher than limits for some of the other disposition pathways currently available. At this time, these scoping tests did not evaluate the partitioning of the radionuclides to the evaporator condensate, since ample data are available separately from other experience in the DOE complex. Results from the evaporation testing show that the neutral SBS simulant first forms turbidity at ~7.5X concentration, while the alkaline-adjusted simulant became turbid at ~3X concentration. The major solid in both cases was Kogarkoite, Na3FSO4. Sodium and lithium fluorides were also detected. Minimal solids were formed in the evaporator bottoms until a substantial fraction of liquid was removed, indicating that evaporation could minimize storage volume issues. Achievable concentration factors without significant insoluble solids were 17X at alkaline pH, and 23X at neutral pH. In both runs, significant ammonia carried over and was captured in the condenser with the water condensate. Results also indicate that with low insoluble solids formation in the initial testing at neutral pH, the use of Reverse Osmosis is a potential alternate method for concentrating the solution, although an evaluation is needed to identify equipment that can tolerate insoluble solids. Most of the ammonia remains in the evaporator bottoms during the neutral pH evaporation, but partitions to the condensate during alkaline evaporation. Disposition of both streams needs to consider the management of ammonia vapor and its release. Since this is an initial phase of testing, additional tasks related to evaporation methods are expected to be identified for development. These tasks likely include evaluation and testing of composition variability testing and evaluations, corrosion and erosion testing, slurry storage and immobilization investigations, and evaporator condensate disposition.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Testing of an Iodine and Tritium Capture System for an NO₂-Based Tritium Pretreatment Process

The reprocessing of used nuclear fuel would release volatile radionuclides into the off-gas streams of a processing plant, including ³H, ¹⁴C, ⁸⁵Kr, and ¹²⁹I. One potential simplification to the management of the off-gas streams could be achieved through an efficient tritium pretreatment (TPT) step in which the UO₂ fuel is oxidized by either air or NO₂ before dissolution. The oxidation of the UO₂ fuel matrix will result in the release of tritium from the fuel. Upfront release of tritium from the fuel in a pretreatment step with subsequent tritium abatement can minimize or eliminate the distribution of tritium throughout a plant. This can decrease or eliminate the need for tritium capture on multiple off-gas streams and prevent distribution to the aqueous inventory. The use of NO₂ as the oxidant in an advanced tritium pretreatment (ATPT) allows for the oxidation to be performed at lower temperatures and may also result in the quantitative release of iodine from the fuel. The ATPT off-gas will contain up to 75 vol% NO₂ gas. Spencer et al. identified the most promising iodine sorbent as silver nitrate-impregnated alumina (AgA) and the most promising tritium sorbents as 3Å molecular sieve (3Å MS) and silica gel for radionuclide capture from ATPT off-gas streams. An initial series of tests were conducted in fiscal years 2017–2018 with the intent of demonstrating the recovery of iodine and tritium using these sorbents from a recirculating gas stream that simulated the NO₂ recycle loop envisioned for the ATPT system. These initial tests showed low tritium recoveries and significant variations in the iodine recovery on the AgA. Ultimately it was concluded, following disassembly of the system, that corrosion within the system was partially the cause of the poor recovery of both species. All components of that system were disposed of at the end of the analysis. One of the conclusions drawn from the initial tests pointed to the reconsideration of the materials of construction. Based on that recommendation a new test bed for the advanced TPT off-gas system, that addresses the issues identified in the fiscal years 2017 and 2018 scoping tests, was designed and constructed. The test bed used high nickel alloys wherever possible to address the previously observed corrosion issues, a redesigned surge tank to permit ease of purging, an improved feed injection system and a more modular system design that allowed testing of incremental increases in system complexity to allow the isolation of any element that results in changes to recovery of target species. Accompanying that design, a multifaceted test plan was completed. The overarching goals of this test series were two-fold. The first goal was to demonstrate the ability to recover both the iodine and tritium that would be released during TPT in a manner that the releases from the fuel can be quantified. The second goal was to demonstrate that the combined recovery system could operate in any of the three proposed TPT modes (once-through air or O₂, recirculating air or O₂, or recirculating NO x ). A total of 22 tests were completed. Ten tests examined tritium behavior under varying operating parameters, 8 tests examined iodine behavior under varying operating parameters, and 4 tests examined both tritium and iodine behavior. Silica gel was used for the tritium sorbent, and AgA or Ag-mordenite (AgZ) was used as the iodine sorbent. The following conclusions were drawn: Full recovery is achieved for both sorbates when no sorbent is in place indicating no accumulation within the test system. In even the simplest of the configurations (i.e., no sorbents in the columns), iodine is more difficult to transport and recover from the system than tritium. Analysis of the AgA iodine sorbent beds from the integrated tritium and iodine tests indicate quantitative iodine recovery can be achieved (within anticipated experimental errors). This system may provide a means for the quantification of the iodine released by the ATPT process within the experimental uncertainties. This would support 0.33 to 1.00 kg demonstrations of the ATPT process with actual used nuclear fuel. Iodine penetrated further into AgZ than into AgA when operated in gas recirculation mode. Tritium adsorbs to and cannot be fully recovered from the 10-cm column of silica gel at regeneration temperatures up to 140 °C.; Tritium adsorbs to and cannot be recovered from the 10-cm column of AgA at desorption temperatures up to 200 °C. Co-adsorbed tritium was recovered to a greater extent from AgZ than from AgA, but recovery was not complete. No visible corrosion was observed in the test system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Out-of-Pile Testing of Radiation Hard Optical Fibers

The work detailed in this report was supported under the In-Pile Instrumentation program for FY19. The work was conducted by researchers at Boise State University (BSU) and Idaho National Laboratory (INL). This report describes the out-of-pile testing that has been conducted to help guide sensor design and data interpretation by providing a robust understanding of out-of-pile fiber optic performance under different environmental factors. Highlighted in this report are two test configurations, transmission testing of optical fibers over a range of temperatures, and tensile testing of optical fibers identified through prior research as having potential for in-core use. The transmission temperature testing is conducted with high spectral resolution to study the influence of elevated temperatures on transmission. This testing has been conducted from room temperature up to 800ºC. The transmission testing was conducted by BSU at the Fiber Laser and Integrated photonics Research (FLaIR) laboratory. This testing will allow separation of radiation and temperature effects during in-core testing and allow for a more thorough understanding of radiation effects on fiber sensors. The tensile testing of optical fibers was conducted to provide a baseline for the strength of fiber optics. The fragile nature of glass fibers is a limitation in the deployment of fiber optics. Furthermore, intrinsic fiber optic sensors such as Fiber Bragg Gratings (FBG) add defects or damaged areas to the fiber which reduce its strength and can lead to broken sensors if not handled with care. The thermo-mechanical test facility enables the ability to quantitatively measure the strength of fibers with and without FBG’s over a temperature range. This information will be used to determine which types of FBG’s, and other sensors, are likely to survive the installation process. These tests will also be used to characterize the potential measurement range of fiber based strain sensors. The tensile testing was completed at INL in the HTTL Fiber Optics and Ultrasonic Technologies (FOUT) laboratory. Pure silica core (PSC) optical fibers have been shown to perform well in harsh environments. Transmission testing and tensile testing showed little change in fiber dynamic strength and transmission with elevated temperatures. There was no significant weakening of the fiber for temperatures up to 200ºC. Transmission at 1550 nm (a common wavelength used for optical sensors) showed minimal changes up to 800ºC with some improvement after 12 hours of annealing at 800ºC. This indicates that PSC optical fiber is a good candidate for in-pile testing.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Improvements to the New CTH Code Verification & Validation Test Suite (FY2020)

The CTH multiphysics hydrocode, which is used for a wide range of important calculations, has undertaken in recent years to overhaul its software quality and testing processes. A key part of this effort entailed building a new, robust V&V test suite made up of traditional hydrocode verification problems, such as those listed in the ASC Tri-Lab Test Suite and the Enhanced Tri-Lab Test Suite, as well as validation problems for some of CTHs most frequently used equations of state, materials models, and other key capabilities. Substantial progress towards this goal was made in FY19. In FY20, this test suite has been expanded to include verification and validation tests of the Sesame and JWL equation of state models as well as the Mader verification problem from the Tri-Lab Test Suite and the Blake verification problem - a linear elastic analog to the Hunter problem from the Enhanced Tri-Lab Test Suite. This report documents CTH performance on the new test suite problems. Verification test results are compared to analytic solutions and, for most tests, convergence results are presented. Validation test results are compared to experimental data and mesh refinement studies are included. CTH performs well overall on the new test problems. Convergence rates for the Blake and Mader problems are comparable to those for similar ASC codes. The JWL and Sesame verification tests show good agreement with analytic solutions. Likewise, CTH simulation results show good agreement with experimental validation data for the Sesame and JWL equations of state for the materials tested. Future V&V work will focus on adding tests for other key capabilities like fracture and high explosive models.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

International Benchmarking: A Global Perspective of Workplace Drug and Alcohol Testing

Workplace drug and alcohol testing has been widely implemented in diverse industries and is designed to detect the use of and deter the influence of legal and illegal substances that would impair the ability to perform work that has significant security and safety implications. Across the globe, patterns of drug and alcohol use and abuse and the regulations controlling drug and alcohol use vary by location (e.g., regions, countries, etc.). The prevalence of workplace drug and alcohol testing and protection of individuals’ rights in the workplace similarly tend to exhibit contextual differences. With the advancements in drug-testing technologies and the recent issuance of guidance for additional testing matrices (e.g., oral fluid, hair, etc.) by the U.S. Department of Health and Human Services, gaining a global perspective on the current state of drug and alcohol testing practices and regulations is important for leveraging such advancements to improve the effectiveness of drug and alcohol testing. The U.S. Nuclear Regulatory Commission (NRC) tasked the Pacific Northwest National Laboratory (PNNL) fitness for duty (FFD) team to conduct a benchmarking analysis of international drug and alcohol testing regulations and programs to identify similarities and differences in workplace testing programs and the basis for any differences. The benchmarking study focuses on a policy analysis and benchmarking metrics comparison among different countries and regions. The policy analysis includes the following three types of relevant international and national policies relevant to drug and alcohol testing in the nuclear industry: 1. National drug and alcohol policy 2. Workplace drug and alcohol testing 3. FFD regulations for Nuclear Power Plants The international drug and alcohol benchmarking metrics focusses on the use of blood, breath, urine, hair, and oral fluid in testing; drug and drug metabolite cutoff values; point-of-collection testing devices; roadside testing methodologies; innovations in drug testing; and the extent of availability of such data. Gaining an understanding of workplace drug and alcohol testing in other countries as well as information about new testing methods, matrices, tools, and technologies that other countries have adopted provides NRC with international comparative information regarding the technical basis for such programs and methods as it relates to the protection of worker and public health and safety.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗