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At least 19 records

Multileaf collimator performance monitoring and improvement using semiautomated quality control testing and statistical process control

Purpose: High-quality radiation therapy using highly conformal dose distributions and image-guided techniques requires optimum machine delivery performance. In this work, a monitoring system for multileaf collimator (MLC) performance, integrating semiautomated MLC quality control (QC) tests and statistical process control tools, was developed. The MLC performance monitoring system was used for almost a year on two commercially available MLC models. Control charts were used to establish MLC performance and assess test frequency required to achieve a given level of performance. MLC-related interlocks and servicing events were recorded during the monitoring period and were investigated as indicators of MLC performance variations. Methods: The QC test developed as part of the MLC performance monitoring system uses 2D megavoltage images (acquired using an electronic portal imaging device) of 23 fields to determine the location of the leaves with respect to the radiation isocenter. The precision of the MLC performance monitoring QC test and the MLC itself was assessed by detecting the MLC leaf positions on 127 megavoltage images of a static field. After initial calibration, the MLC performance monitoring QC test was performed 3–4 times/week over a period of 10–11 months to monitor positional accuracy of individual leaves for two different MLC models. Analysis of test results was performed using individuals control charts per leaf with control limits computed based on the measurements as well as two sets of specifications of ±0.5 and ±1 mm. Out-of-specification and out-of-control leaves were automatically flagged by the monitoring system and reviewed monthly by physicists. MLC-related interlocks reported by the linear accelerator and servicing events were recorded to help identify potential causes of nonrandom MLC leaf positioning variations. Results: The precision of the MLC performance monitoring QC test and the MLC itself was within ±0.22 mm for most MLC leaves and the majority of the apparent leaf motion was attributed to beam spot displacements between irradiations. The MLC QC test was performed 193 and 162 times over the monitoring period for the studied units and recalibration had to be repeated up to three times on one of these units. For both units, rate of MLC interlocks was moderately associated with MLC servicing events. The strongest association with the MLC performance was observed between the MLC servicing events and the total number of out-of-control leaves. The average elapsed time for which the number of out-of-specification or out-of-control leaves was within a given performance threshold was computed and used to assess adequacy of MLC test frequency. Conclusions: A MLC performance monitoring system has been developed and implemented to acquire high-quality QC data at high frequency. This is enabled by the relatively short acquisition time for the images and automatic image analysis. The monitoring system was also used to record and track the rate of MLC-related interlocks and servicing events. MLC performances for two commercially available MLC models have been assessed and the results support monthly test frequency for widely accepted ±1 mm specifications. Higher QC test frequency is however required to maintain tighter specification and in-control behavior.

07 ISOTOPE AND RADIATION SOURCES↗

Assessment of Controlling Processes for Field-Scale Uranium Reactive Transport under Highly Transient Flow Conditions

This paper presents the results of a comprehensive model-based analysis of a uranium tracer test conducted at the U.S Department of Energy Hanford 300 Area (300A) IFRC site. A three-dimensional multi-component reactive transport model was employed to assess the key factors and processes that control the field-scale uranium reactive transport. Taking into consideration of relevant physical and chemical processes, the selected conceptual/numerical model replicates the spatial and temporal variations of the observed U(VI) concentrations reasonably well in spite of the highly complex field conditions. A sensitivity analysis was performed to interrogate the relative importance of various processes and factors for reactive transport of U(VI) at the field-scale. The results indicate that multi-rate U(VI) sorption/desorption, U(VI) surface complexation reactions, and initial U(VI) concentrations were the most important processes and factors controlling U(VI) migration. On the other hand, cation exchange reactions, the choice of the surface complexation model, and dual-domain mass transfer processes, which were previously identified to be important in laboratory experiments, played less important roles under the field-scale experimental condition at the 300A site. However, the model simulations also revealed that the groundwater chemistry was relatively stable during the uranium tracer experiment and therefore presumably not dynamic enough to appropriately assess the effects of ion exchange reaction and the choice of surface complexation models on U(VI) sorption and desorption. Furthermore, it also showed that the field experimental duration (16 days) was not sufficiently long to precisely assess the role of a majority of the sorption sites that were accessed by slow kinetic processes within the dual domain model. The sensitivity analysis revealed the crucial role of the intraborehole flow that occurred within the long-screened monitoring wells and thus significantly affected both field-scale measurements and simulated U(VI) concentrations as a combined effect of aquifer heterogeneity and highly dynamic flow conditions. Overall, this study, which provides one of the few detailed and highly data-constrained uranium transport simulations, highlights the difference in controlling processes between laboratory and field scale that prevent a simple direct upscaling of laboratory-scale models.

07 ISOTOPE AND RADIATION SOURCES↗

Quality Control of High-Dose-Rate Brachytherapy: Treatment Delivery Analysis Using Statistical Process Control

Purpose: Statistical process control (SPC) is a quality control method used to ensure that a process is well controlled and operates with little variation. This study determined whether SPC was a viable technique for evaluating the proper operation of a high-dose-rate (HDR) brachytherapy treatment delivery system. Methods and Materials: A surrogate prostate patient was developed using Vyse ordnance gelatin. A total of 10 metal oxide semiconductor field-effect transistors (MOSFETs) were placed from prostate base to apex. Computed tomography guidance was used to accurately position the first detector in each train at the base. The plan consisted of 12 needles with 129 dwell positions delivering a prescribed peripheral dose of 200 cGy. Sixteen accurate treatment trials were delivered as planned. Subsequently, a number of treatments were delivered with errors introduced, including wrong patient, wrong source calibration, wrong connection sequence, single needle displaced inferiorly 5 mm, and entire implant displaced 2 mm and 4 mm inferiorly. Two process behavior charts (PBC), an individual and a moving range chart, were developed for each dosimeter location. Results: There were 4 false positives resulting from 160 measurements from 16 accurately delivered treatments. For the inaccurately delivered treatments, the PBC indicated that measurements made at the periphery and apex (regions of high-dose gradient) were much more sensitive to treatment delivery errors. All errors introduced were correctly identified by either the individual or the moving range PBC in the apex region. Measurements at the urethra and base were less sensitive to errors. Conclusions: SPC is a viable method for assessing the quality of HDR treatment delivery. Further development is necessary to determine the most effective dose sampling, to ensure reproducible evaluation of treatment delivery accuracy.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

SU-D-BRD-07: Evaluation of the Effectiveness of Statistical Process Control Methods to Detect Systematic Errors For Routine Electron Energy Verification

Purpose: To evaluate the ability of statistical process control methods to detect systematic errors when using a two dimensional (2D) detector array for routine electron beam energy verification. Methods: Electron beam energy constancy was measured using an aluminum wedge and a 2D diode array on four linear accelerators. Process control limits were established. Measurements were recorded in control charts and compared with both calculated process control limits and TG-142 recommended specification limits. The data was tested for normality, process capability and process acceptability. Additional measurements were recorded while systematic errors were intentionally introduced. Systematic errors included shifts in the alignment of the wedge, incorrect orientation of the wedge, and incorrect array calibration. Results: Control limits calculated for each beam were smaller than the recommended specification limits. Process capability and process acceptability ratios were greater than one in all cases. All data was normally distributed. Shifts in the alignment of the wedge were most apparent for low energies. The smallest shift (0.5 mm) was detectable using process control limits in some cases, while the largest shift (2 mm) was detectable using specification limits in only one case. The wedge orientation tested did not affect the measurements as this did not affect the thickness of aluminum over the detectors of interest. Array calibration dependence varied with energy and selected array calibration. 6 MeV was the least sensitive to array calibration selection while 16 MeV was the most sensitive. Conclusion: Statistical process control methods demonstrated that the data distribution was normally distributed, the process was capable of meeting specifications, and that the process was centered within the specification limits. Though not all systematic errors were distinguishable from random errors, process control limits increased the ability to detect systematic errors using routine measurement of electron beam energy constancy.

07 ISOTOPE AND RADIATION SOURCES↗

Process Control Approach to Implement High Waste Loading Glass Formulations for Hanford Low Activity Waste Vitrification - 18435

Acceptable glass formulations for vitrification of Hanford low activity waste (LAW) at The Hanford Tank Waste Treatment and Immobilization Plant (WTP) must meet a variety of product quality, processability, and waste loading requirements. The glass formulation development work underpinning the WTP baseline LAW glasses was captured in a vitrification process control approach developed by the Vitreous State Laboratory (VSL) and Atkins Energy Federal EPC, Inc. that permits the calculation of the glass formulation required for each particular batch of LAW delivered to the LAW vitrification facility. Since that time, we have developed a wide range of glass formulations that achieve considerably higher waste loadings and which therefore are more economically attractive in terms of reduced amounts of glass produced and decreased time for treatment. That work was done in support of the Department of Energy's Office of River Protection program that is examining options to optimize the LAW facility and LAW glass waste form. Implementation of these high waste loading formulations at the WTP requires the development of a new LAW vitrification process control algorithm, which is the subject of this paper. Waste loadings in LAW glasses are typically limited by either the alkali loading for LAW with low sulfate content or the SO{sub 3} loading for LAW with high sulfate content. In the former case, waste loadings are limited by refractory corrosion and glass corrosion on the vapor hydration test (VHT) and product consistency test (PCT), all of which tend to increase with higher alkali concentrations. In the latter case, waste loadings are limited by the formation of a molten sulfate phase in the melter, which has deleterious effects. The LAW vitrification process control strategy must mitigate these effects while optimizing waste loadings. Given the composition of any LAW stream, the new LAW vitrification process control algorithm permits the calculation of a suitable high waste loading glass composition and the required glass forming additives such that all processing, waste loading, and product quality requirements are met. This algorithm was developed from data for a large number of glasses that were formulated, and characterized with respect to a variety of properties affecting processability and product quality; many of these formulations were also subjected to melter testing to verify acceptable processing characteristics, processing rates, and the absence of secondary sulfate phase formation. This paper describes the development of the present algorithm, comparisons to the present lower waste loading baseline WTP process control approach, and plans for further development and testing. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

In‐mold rheology and automated process control for injection molding of recycled polypropylene

Abstract Manufacturing plastic parts with secondary feedstocks has risen to the forefront of importance in recent years. However, the variation in molecular weight and rheology of secondary feedstock can lead to inconsistent part quality. This work evaluates the effectiveness of a novel closed‐loop adaptive process control system that adjusts nozzle pressure in response to in‐mold pressure data. Five different recycled polypropylene blends, with a broad distribution of flow properties, were evaluated to determine the effectiveness of the control system at reducing processing variation. The experimental results show that the process control strategy reduced the variation within the mold, as seen by in‐mold pressure curves and calculated in‐mold viscosity values. Additionally, the parameters that control the automated process adjustments were investigated, showing the importance of optimization. The analysis of the correlation between in‐mold rheology and mechanical properties showed a slight variation in the mechanical properties and parts weight with a coefficient of variation of under 5%. Overall, the results demonstrate the ability of pressure‐controlled molding and automated viscosity adjustment to reduce the variability when molding a secondary feedstock. Highlights Pressure‐controlled injection molding of recycled polypropylene. Automated closed‐loop adaptive process control methodology. Methodology resulted in a reduction in pressure variation during molding. Changes in mechanical properties and in‐mold viscosity were investigated. Results show the potential of pressure‐controlled molding at reducing variation.

Krantz, Joshua↗

In-Situ Powder-Directed Energy Process Control for Additively Manufactured Multi-Layer, Functionally Graded Components

Coatings and cladding can experience damage in harsh environments: Erosion Oxidation Delamination External mechanical damage Radiation induced damage Functionally Graded Materials (FGMs) were primarily designed to reduce thermal stress in thermal barrier coatings (TBCs), but can produce coatings which resist a variety of material damage (corrosion, surface damage, diffusion) Powder-fed DED with multiple independent feeders allows for AM FGMs, and provides robust control over process parameters to optimize microstructure and performance. FGMs have a great opportunity for applications in energy applications as a strategy to increase plant efficiency and lifetime.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Characterisation of strain-induced precipitation behaviour in microalloyed steels during thermomechanical controlled processing

The temperature at which thermomechanical controlled processing is undertaken strongly influences strain-induced precipitation (SIP) in microalloyed steels. In this study, the recrystallisation-precipitation-time-temperature curve was simulated to determine the full recrystallisation temperature, recrystallisation-stop temperature and the temperature where precipitation would occur at the shortest time. The calculated temperatures were verified by experimental testing for rolling between 1100 °C and 850 °C. On the basis of this a finishing deformation of 850 °C was chosen in order to maximise the precipitate number density formed in a fully unrecrystallised austenite. The orientation relationship between the SIP in austenite, and subsequent transformation to ferrite was identified by calculation from the coordinate transformation matrix, and by electron diffraction in the transmission electron microscope. The NbC formed as coherent/semi-coherent precipitates in the austenite, and remained coherent/semi-coherent in the ferrite, indicating a Kurdjumov-Sachs orientation relationship between the austenite and ferrite on transformation. - Highlights: •The austenite deformation temperature will influence strain-induced precipitation. •Precipitates are NbC, exhibiting an NaCl structure and lattice parameter 0.447 nm. •Fine NbC (< 10 nm) formed in austenite as coherent or semi-coherent precipitates. •Confirmed cube-on-cube orientation relationship between the NbC, the austenite and the ferrite.

36 MATERIALS SCIENCE↗

A Prototyping Environment for Research on Human-Machine Interfaces in Process Control: Use of Microsoft WPF for Microworld and Distributed Control System Development

Operators of critical processes, such as nuclear power production, must contend with highly complex systems, procedures, and regulations. Developing human-machine interfaces (HMIs) that better support operators is a high priority for ensuring the safe and reliable operation of critical processes. Human factors engineering (HFE) provides a rich and mature set of tools for evaluating the performance of HMIs, but the set of tools for developing and designing HMIs is still in its infancy. Here we propose that Microsoft Windows Presentation Foundation (WPF) is well suited for many roles in the research and development of HMIs for process control.

99 GENERAL AND MISCELLANEOUS↗

OWL Change Control Process

The Online Waste Library (OWL) provides a consolidated source of information on Department of Energy-managed radioactive waste likely to require deep geologic disposal. With the release of OWL Version 1.0 in fiscal year 2019 (FY2019), much of the FY2020 work involved developing the OWL change control process and the OWL release process. These two processes (in draft form) were put into use for OWL Version 2.0, which was released in early FY2021. With the knowledge gained, the OWL team refined and documented the two processes in two separate reports. This report focuses on the change control process and discusses the following: (1) definitions and system components; (2) roles and responsibilities; (3) origin of changes; (4) the change control process including the Change List, Task List, activity categories, implementation examples, and checking and review; and (5) the role of the re lease process in ensuring changes in the Change List are incorporated into a public release.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Fermentation process using specific oxygen uptake rates as a process control

Specific oxygen uptake (OUR) is used as a process control parameter in fermentation processes. OUR is determined during at least the production phase of a fermentation process, and process parameters are adjusted to maintain the OUR within desired ranges. The invention is particularly applicable when the fermentation is conducted using a microorganism having a natural PDC pathway that has been disrupted so that it no longer functions. Microorganisms of this sort often produce poorly under strictly anaerobic conditions. Microaeration controlled by monitoring OUR allows the performance of the microorganism to be optimized.

59 BASIC BIOLOGICAL SCIENCES↗

Fermentation process using specific oxygen uptake rates as a process control

Specific oxygen uptake (OUR) is used as a process control parameter in fermentation processes. OUR is determined during at least the production phase of a fermentation process, and process parameters are adjusted to maintain the OUR within desired ranges. The invention is particularly applicable when the fermentation is conducted using a microorganism having a natural PDC pathway that has been disrupted so that it no longer functions. Microorganisms of this sort often produce poorly under strictly anaerobic conditions. Microaeration controlled by monitoring OUR allows the performance of the microorganism to be optimized.

59 BASIC BIOLOGICAL SCIENCES↗

The Alliance of Advanced Process Control and Accountability – A Future Safeguards-By-Design Tool

For any chemical separation process producing a valuable product, a material balance is an important process control measurement. That is particularly true for the separation of actinides from irradiated nuclear fuel, not only for their intrinsic value but also because an incomplete material balance may indicate diversion for unauthorized use. The DOE Office of Nuclear Energy is currently carrying out at the Pacific Northwest National Laboratory an experimental measurement of how well and with what precision current technologies can implement near real-time actinide material balances. This measurement effort is called the CoDCon project. It involves the separation of a product with a 70/30 uranium/plutonium mass ratio. Initial tests will use dissolved fuel simulants prepared with pure uranium and plutonium nitrates at the same input ratios as irradiated fuel. Subsequent testing with actual irradiated fuel would be done to verify the results obtained with simulants. The experiments will use advanced on-line instrumentation supported by dynamic process models. Since accountability uncertainties could mask diversions, the aim of the project is not only to measure present-day capabilities but also, through sensitivity analyses, to identify those measurements with the greatest potential for overall material-balance improvements. The latter results will help identify priorities for future fuel cycle R&D programs. Advanced separations process control and material accountability technologies thus have a common goal: to provide the best tools available for safeguards-by-design [defined by the International Atomic Energy Agency (IAEA) as the integration of the design of a new nuclear facility through planning, construction, operation and decommissioning]. Since the potential domestic use of CoDCon results may be later than their possible foreign applications, arrangements may be feasible for possible bilateral or multinational cooperation in the CoDCon project.

Lumetta, Gregg J.↗

Quantification of UV-Visible and Laser Spectroscopic Techniques for Materials Accountability and Process Control

Ultraviolet–visible spectroscopy (UV–Visible) and time-resolved laser fluorescence spectroscopy (TRLFS) optical techniques can permit on-line analysis of actinide elements in a solvent extraction process in real time. These techniques have been used for measuring actinide speciation and concentration under laboratory conditions and are easily adaptable to multiple sampling geometries, such as dip probes, fiber-optic sample cells, and flow-through cell geometries. To fully exploit these techniques, researchers must determine the fundamental speciation of target actinides and the resulting influence on spectroscopic properties. Detection limits, process conditions, and speciation of key actinide components can be established and utilized in a range of areas, particularly those related to materials accountability and process control. Through this project, researchers will develop tools and spectroscopic techniques to evaluate solution extraction conditions and concentrations of U, Pu, and Cm in extraction processes, addressing areas of process control and materials accountability. The team will evaluate UV– Visible and TRLFS for use in solvent extraction-based separations. Ongoing research is examining efficacy of UV-Visible spectroscopy to evaluate uranium and plutonium speciation under conditions found in the UREX process and using TRLFS to evaluate Cm speciation and concentration in the TALSPEAK process. A uranyl and plutonium nitrate UV–Visible spectroscopy study met with success, which supports the utility and continued exploration of spectroscopic methods for evaluation of actinide concentrations and solution conditions for other aspects of the UREX+ solvent extraction scheme. This project will examine U and Pu absorbance in TRUEX and TALSPEAK, perform detailed examination of Cm in TRUEX and TALSPEAK, study U laser fluorescence, and apply project data to contactors. The team will also determine peak ratios as a function of solution concentrations for the UV-Visible spectroscopy studies. The use of TRLFS to examine Cm and U will provide data to evaluate lifetime, peak location, and peak ratios (mainly for U). The bases for the spectroscopic techniques have been investigated, providing fundamental evidence for the application’s utility.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

SU-D-201-04: Evaluation of Elekta Agility MLC Performance Using Statistical Process Control

Purpose: to evaluate the performance and stability of the Elekta Agility MLC model using an automated quality control (QC) test in combination with statistical process control tools. Methods: Leaf positions were collected daily for 11 Elekta units over 5–19 months using the automated QC test, which analyzes 23 MV images to determine the location of MLC leaves relative to the radiation isocenter. The leaf positions are measured at 5 nominal positions, and images are acquired at collimator 0° and 180° to capture all MLC leaves in the field-of-view. Leaf positioning accuracy was assessed using individual and moving range control charts. Control limits were recomputed following MLC recalibration (occurred 1–2 times for 4 units). Specification levels of ±0.5, ±1 and ±1.5mm were tested. The mean and range of duration between out-of-control and out-of-specification events were determined. Results: Leaf position varied little over time, as confirmed by very tight individual control limits (mean ±0.19mm, range 0.09–0.44). Mean leaf position error was −0.03mm (range −0.89–0.83). Due to sporadic out-of-control events, the mean in-control duration was 3.3 days (range 1–23). Data stayed within ±1mm specification for 205 days on average (range 3–372) and within ±1.5mm for the entire date range. Measurements stayed within ±0.5mm for 1 day on average (range 0–17); however, our MLC leaves were not calibrated to this level of accuracy. Conclusion: The Elekta Agility MLC model was found to perform with high stability, as evidenced by the tight control limits. The in-specification durations support the current recommendation of monthly MLC QC tests with a ±1mm tolerance. Future work is on-going to determine if Agility performance can be optimized further using high-frequency QC test results to drive recalibration frequency. Factors that can affect leaf positioning accuracy, including beam spot motion, leaf gain calibration, drifting leaves, and image artifacts, are under investigation.

60 APPLIED LIFE SCIENCES↗