Engineering topics

Glass, Samuel W.

Publications and source records attributed to Glass, Samuel W..

At least 37 records · Page 2

DOE OSTI2022

Temperature Dependence of FDR Response for Thermally Aged Low-Voltage Cables

Frequency Domain Reflectometry (FDR) has attracted significant attention for use in nuclear power plants (NPPs) for non-destructive cable health monitoring. However, cable aging detection using FDR faces challenges due to its high sensitivity to environmental factors such as temperature, vibrations, proximity to other cables, and so on. This work aims to evaluate the influence of measurement temperature on the FDR reflected signal in a low voltage cable undergoing accelerated thermal aging. A 100 ft long multi-core low-voltage unshielded power cable insulated with flame retardant ethylene propylene rubber (FR-EPR) and covered by a chloro-polyethylene (CPE) jacket was selected for this study. The cable was energized during aging by a 480 VAC 3-phase motor, and a 30 ft mid-section of this cable was routed through an air circulating oven held at 140 °C for up to an effective aging time of 62 days. FDR measurements were taken periodically with the oven on (at 140 °C) and with the oven off (at 22 °C). A comparative analysis of data collected at both temperatures showed that the FDR response was strongly dependent on measurement temperature. FDR measurements at ambient temperature showed large peaks corresponding to impedance changes in the aged section of the cable after 3 days of aging. These peaks continued to rise steadily with increasing aging time. However, for measurements taken at 140 °C, slowly rising peaks in the oven region (aged section) were observed only after a lead time of 23 days of aging. This work highlights the importance of measurement temperature on the performance of FDR as a condition monitoring tool for aging cables.

Sriraman, Aishwarya↗

DOE OSTI2022

3D Frequency Domain Reflectometry Digital Twin of an Electrical Cable: A First Glance

Electrical cables within nuclear power plants (NPPs) are critical components required for power, control, and instrumentation systems which may be exposed to stressors, such as elevated temperatures and gamma radiation. Such stressors can lead to a reduction in the remaining useful life of electrical cables, jeopardizing the safety of NPP systems. To evaluate the effect of stressors on the degradation of electrical cables, electrical reflectometry methods are commonly employed. Frequency domain reflectometry (FDR) is a non-destructive electrical reflectometry method that uses transmission line theory to detect degradation or impedance changes within electrical cables. However, in most cases FDR is only applied to de-energized cables, limiting the application in NPPs as the cable system must be taken offline. In this work, we explore the development of an FDR digital twin to predict the degradation of an electrical cable exposed to elevated temperature, which is expected to reduce the need for offline FDR. A 3-conductor low-voltage electrical cable was selected for evaluation of the digital twin. The fully three-dimensional digital twin was developed in COMSOL using the RF module. A cable length of 30-m and frequency bandwidth of 400 MHz was selected to mimic real-world application of FDR. Over a 1-m region, the permittivity of the insulation was varied by up to 20% to model thermal degradation. The results demonstrate accurate detection of the insulation damage region, supporting further investigation of the FDR digital twin using real-world data and machine learning for predictive damage estimation or remaining lifetime.

Spencer, Mychal P.↗

DOE OSTI2022

Miniature Crack or Damage Detection on Cable Insulation and Jacket Using Conformal Surface Wave Reflectometry

This letter introduces the study and application of a conformal surface wave launcher array to detect miniature insulation and/or jacket damage on unshielded cables. Here simulation and experimental results are presented that demonstrate that with the proposed concept very small instances of damage at various distances along power cables can be detected. Effects of damage detection feasibility in the presence of other cables in proximity and for cables containing semiconducting screen are also presented.

42 ENGINEERING↗

DOE OSTI2022

Nondestructive Evaluation (NDE) of Cable Anomalies using Frequency Domain Reflectometry (FDR) and Spread Spectrum Time Domain Reflectometry (SSTDR)

This report presents a comparative assessment of the performance of frequency domain reflectometry (FDR) and spread spectrum time domain reflectometry (SSTDR) in detecting a wide range of electrical cable anomalies. All tests and results reported herein were performed at the PNNL Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable and motor test bed. The primary objective of this work was to evaluate the effectiveness of SSTDR, a fledgling cable monitoring technique that shows promise for application in online monitoring of energized cable systems, against FDR, an offline technique widely employed in the nuclear power plant (NPP) industry. FDR tests are becoming more widely used in nuclear power plant cable aging management and test programs – particularly for low voltage cables. FDR capabilities for these kinds of tests have been reported by PNNL and others. The FDR test is performed on de-energized cables by connecting the FDR instrument to two of the cable conductors, or one conductor and the shield. A broad band low voltage (< 5 V) chirp is introduced in the cable, and any reflected response is captured in the frequency domain. The captured reflection is then processed by performing an inverse Fourier transform to a time domain response which can then be converted to a distance response based on the cable velocity of propagation (VoP). SSTDR measurements are functionally similar to FDR measurements in that a broad-band voltage signal composed of a square or sine wave modulated pseudo-random sequence of chips (< 5 volts), is injected onto one of the cable conductors. The injected signal will experience partial energy reflection and transmission at each impedance discontinuity along the transmission line. Any reflected response is detected by computing a cross-correlation between the reflected signals and a delayed copy of the incident SSTDR signal. the time delay for the reflected signal to experience the best matched correlation with the incident signal, indicates the travel time for the signal to reach a change in impedance. By knowing this time delay and velocity of propagation (VoP) of the signal, one can compute the physical distance. A big advantage that SSTDR measurements have over other methods is the ability to be connected to energized or live wires (currently up to 1kV) thereby enabling online monitoring of cables. SSTDR has been used successfully in several applications, e.g., aircraft, rail, and photovoltaic systems. In this work FDR and SSTDR cable assessment techniques were used to characterize a variety of cable anomalies and faults including: (1) Presence or absence of a motor; (2) Ground faults and short circuit faults; (3) Moist environments and water ingress faults; (4) Accelerated thermal aging. Both shielded and non-shielded cables were evaluated in this report. Offline measurements were made using FDR and online measurements were made by SSTDR for a range of test scenarios. Based on the results across all cable anomalies evaluated in this study, FDR displayed high sensitivity towards cable condition assessment, while SSTDR showed promise for future application in monitoring NPP cable systems. However, further developments are suggested to improve the resolution and sensitivity of SSTDR towards faults and anomalies in low voltage cables.rt presents a comparative

42 ENGINEERING↗

DOE OSTI2022

Effect of Semiconducting Layer on Cable Insulation Damage Detection Using Surface Wave Reflectometry

This paper presents a study of the effect of the semiconducting layer present in medium and high voltage cables on surface wave propagation and its feasibility in detecting insulation damage on cables. Simulation studies were conducted using Ansys High Frequency Structure Simulator (HFSS). It was observed that attenuation increased with thicker semiconducting layer and higher conductivity of the layer. For instance, on a 24.4 mm diameter power cable, the electric field strength associated with a 1 GHz surface wave declines with distance and fades away after 30 m when a 2 mm thick semiconducting layer is present. More results as a function of semiconducting layer thickness, material conductivity and permittivity, distance of a damaged section, etc. will be presented.

reflectometry, unshielded power cable, semiconduct↗

DOE OSTI2022

Surface Wave Based Non-conductor-contact Reflectometry Method for Insulation and Jacket Damage Detection in Multi-Conductor Cables

This paper presents a non-conductor-contact surface wave reflectometry technique to locate insulation and jacket damage on multi-conductor cables at a distant location from the sensor. Simulation studies were conducted using Ansys high frequency structure simulator (HFSS). A GHz range surface wave launcher was employed such that maximum surface wave energies were confined in the insulation layer while minimizing attenuation. The wave launcher can potentially be mounted on the outer surface of live cables or cable conduits and requires no physical connection to the conductors. Multiple simulations involving a 4 GHz wave launcher and a three-conductor cable with an 8 mm outer diameter were carried out demonstrating the efficacy of the proposed method. Water leak and different types of insulation/jacket damage were simulated and detected.

reflectometry, multi-conductor cable, frequency do↗

DOE OSTI2022

Online Lead/Water Heat Exchanger Sensor/System Feasibility-PNNL (Final Report)

On-line structural health corrosion monitoring in advanced lead fast reactor heat exchangers and molten salt reactor heat exchangers is desirable for detecting tube degradation prior to leaks that may allow mixing of heat exchanger fluids or release of radiological contamination beyond the design containment boundary. This program, On-Line Lead/Water Heat Exchanger Sensor/System Feasibility – PNNL 76092, demonstrates feasibility for an ultrasonic torsional wave mode sensor attached to the outside of a long (30.5-m) heat exchanger tube in the stagnant flow area where the tube joins a heat exchanger plenum and where it is possible to protect a sensor and cable from high-force flows. The sensor must be cable connected to a monitoring instrument near the heat exchanger. The sensor and cable management approach for periodic in-service inspection will be impractical to implement on existing heat exchangers; rather permanently mounted sensors must be installed in conjunction with heat exchanger fabrication. Previous work has shown low-temperature lead zirconate titanate (PZT) piezoceramic sensors are able to detect anomalies of interest in 3.0-m long tubes. These sensors have hereby been extended to a 30.5-m long tube more representative of commercial power heat exchanger designs. The program will continue to investigate higher temperature piezoelectric ceramics and long-term performance of high temperature adhesives and sealants and mechanical pressure coupling for 350-500 °C lead reactor environments and higher temperature (700 °C) molten salt environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Non-Conductor-Contact Surface Wave Reflectometry for Cable Insulation Damage Detection

Here, this paper presents a non-conductor-contact surface wave-based reflectometry technique to detect and locate missing or damaged insulation and/or jacket of electrical cables. The described sensor may be uniquely and practically implemented on live cables as a non-destructive evaluation (NDE) method since it may be applied to the outer insulation/jacket of a cable and requires no direct contact to the conductor. The innovation lies in a high-frequency surface wave launcher that can introduce broadband signals in the GHz frequencies that insure maximum electromagnetic (EM) energy localization within the insulation and/or jacket material. By further processing the reflection data in the frequency domain, the location and severity of insulation damage is detected. Simulated results of thin, thick, short, and long cables show the results expected from small, medium, and large damage regions. For example, the detection of 40 mm-long damage region at 40 m distance on a 50 m long cable (2.44 cm diameter) is demonstrated. Experimental results are presented that validate simulation findings.

Non Destructive Evaluation↗

DOE OSTI2021

Transition to Online Cable Insulation Condition Monitoring

Nuclear power plant cables were originally qualified for 40 year life and generally have not required specific test verification to assure service availability through the initial plant qualification period. However, license renewals to 60 and 80 years of operation require a cable aging management program that depends on some form of test and verification to assure fitness for service. Environmental stress (temperature, radiation, chemicals, water, and mechanical) varies dramatically within a nuclear power plant and, in some cases, cables have degraded and required repair or replacement before their qualified end-of-life period. In other cases, cable conditions have been mild and dependable cable performance confirmed to extend well beyond the initial qualified life. Most offline performance-based testing requires cables to be de-coupled and de-energized for specially trained technicians to perform testing. These offline tests constitute an expensive operational burden that limits the economic viability of nuclear power plants. Although initial investment may be higher, new online test practices are emerging as options or complements to offline testing that avoid or minimize the regularly scheduled offline test burden. These online methods include electrical and fiber-optic partial discharge measurement, spread spectrum time or frequency domain reflectometry, distributed temperature profile measurements, and local interdigital capacitance measurement of insulation characteristics. Introduction of these methods must be supported by research to confirm efficacy plus either publicly financed or market driven investment to support the start-up expense of cost-effective instrumentation to monitor cable condition and assure reliable operation. This work summarizes various online cable assessment technologies plus introduces a new cable motor test bed to assess some of these technologies in a controlled test environment.

Glass, Samuel W.↗

DOE OSTI2021

Feasibility of Lead Fast Reactor Heat Exchanger Tube Online Monitoring

Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, wedges vs. direct application of piezoelectric sensors, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.

On-Line Tube Monitor, Guided Wave Ultrasound, SH-0↗

DOE OSTI2021

Full-Wave and Circuit-Based Simulations of Cable Insulation Aging/Damage Using Time-Frequency Domain Reflectometry

This paper presents a combined full-wave and circuit-based simulation study to investigate the important topic of cable insulation aging and physical damage. The analysis employs the time-frequency domain reflectometry (TFDR) technique that combines the advantages of both time domain reflectometry (TDR) and frequency domain reflectometry (FDR) for improved location identification and feature resolution. Coaxial cable sections with a location containing insulation aging or physical damage are simulated using Ansys High Frequency Structure Simulator (HFSS). Simulated scattering (S) parameters are then imported into the Advanced Design System (ADS) solver for time domain simulation where a Gaussian windowed chirp signal or ‘chirplet’ is launched. Finally, continuous wavelet transform (CWT) is applied in MATLAB to perform time-frequency analysis of the reflected waveforms. The results reveal that a small change in the relative permittivity of the insulation or the presence of a small point of physical damage on the insulation is reflected as a considerable change in the CWT magnitude demonstrating the efficacy of the method.

cable aging, Non Destructive Examination, time-fre↗

DOE OSTI2021

Nondestructive Evaluation (NDE) of Cable Moisture Exposure using Frequency Domain Reflectometry (FDR)

This Pacific Northwest National Laboratory (PNNL) milestone report assesses the capability of frequency domain reflectometry (FDR) to determine electrical cable submergence using PNNL’s Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable/motor test bed. This work includes a review of relevant literature as well as experimental tests. Nuclear power facilities have experienced various electrical cable failures related to water exposure. The current industry response involves actions to de-water cable vaults, manholes, and other cable locations. These efforts require considerable expenditure of resources, which makes it desirable for the industry to have information on cable condition and history regarding their submergence and water exposure (Mantey 2012). Two tests that are gaining favor within the nuclear industry are time-domain reflectometry (TDR) and FDR. These are low-voltage nondestructive tests that can be applied at a cable end. Testing from the cable end is important because local inspection along the cable length is very difficult due to cables being routed within trays, conduits, underground, and through walls. Both TDR and FDR techniques have been shown to locate cable insulation damage due to thermal, radiation, and mechanical damage. FDR measurements are also more sensitive than TDR to temperature changes, low-bend radius bends, and cable contact with various materials, including conductive materials like steel and water. This work evaluates the feasibility to extend FDR testing to characterizing whether an electrical cable is submerged or not and where it may be submerged using PNNL’s ARENA cable/motor test bed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Assessment of Cold Spray Technology for Nuclear Power Applications

This report provides an overview of cold spray (CS) technology as it relates to repair and fabrication of metal alloys in the nuclear power industry. CS is a relatively new technology with applications established in other industries (e.g., aerospace, defense), and greater use of CS is anticipated within the nuclear power industry. This report is prepared in support of the United States Nuclear Regulatory Commission (NRC) Action Plan for Advanced Manufacturing Technologies (AMTs) Rev. 1, which includes objectives to identify the AMTs most likely to be used for nuclear power applications that require NRC approval, and to prepare NRC staff to review regulatory submittals containing components manufacturing using AMTs. In addition to providing an overview of CS technology, this report highlights engineering and scientific knowledge gaps of CS and rates the size of the knowledge gaps. It also assesses importance rankings of the knowledge gaps as they relate to several application categories. The application categories considered in this exercise include factory-applied CS for chloride induced stress corrosion cracking (CISCC) mitigation, field CISCC repair, light water reactor (LWR) factory structural fabrication, and LWR field dimensional restoration and corrosion protection. The combination of a knowledge gap size rating and importance ranking for an application can be used to prioritize additional data or information gathering efforts.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

PNNL ARENA Cable Motor Test Bed Update

A major focus of the Light Water Reactor Sustainability (LWRS) Cable Nondestructive Examination (NDE) 2021 research is to acquire new equipment and integrate it with existing NDE instruments for a cable motor test bed which has been dubbed the Accelerated and Real Time Experimental Nodal Analysis or “ARENA”. All the primary components have been received and are being staged in the 2410 Stevens building on PNNL’s Richland campus. Building modifications to support a plug-in 480VAC receptacle have been completed and details of the system operating procedure (SOP) are in review. The approved SOP is required before the system is energized but is expected before July 2021. The ARENA system will support planned cable tests for 2021 and beyond that cannot conveniently be performed with on-site installations of cable test equipment including: (1) NDE Tests including Frequency Domain Reflectometry (FDR), Time Domain Reflectometry (TDR), Tan Delta (TD) Impedance measurements, Low Frequency Dielectric Spectroscopy (DS) measurements, standard multi-meter resistance checks, withstand tests and other bulk and distributed tests from the instrument panel with and without motors connected. (2) Online energized live wire tests using partial discharge instruments and LIVE-WIRE spread-spectrum TDR instruments. (3) Cable tests with partially submerged cable segments (including ability to submerge live cable segments). (4) Cable tests with partially or completely thermally aged segments (including ability to expose energized cable segments to thermal aging and use online monitoring instruments to monitor cable performance. (5) Ability to introduce low resistance simulations of connector or splice faults to off-line and on-line instrument setups.

42 ENGINEERING↗

DOE OSTI2021

On-Line Lead/Water Heat Exchanger Sensor/System Feasibility: CRADA 462 [Abstract Only]

The purpose of this project is to develop and demonstrate the feasibility of a high-temperature sensor for on-line structural health monitoring (OLSHM) of the novel heat exchanger tubes in the Hydromine lead cooled reactor. The high temperature sensor takes advantage of the Hydromine heat exchanger tube design that has a relatively cool inlet temperature (~ 350 °C) and the tube ends are in an Argon gas blanket rather than being submerged in a corrosive fluid and the tube ends are conveniently accessible from the periphery of the heat exchanger shell.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Flexible Fabric-Based IDC Sensors for Conformal Curved Surface Applications

Interdigital capacitor (IDC) sensors are attractive in-situ sensors that can be used to measure permittivity variations in materials. Such sensors could be powerful enablers for cable insulation aging detection. Since insulation aging is correlated with a change in its material permittivity an IDC can measure that change via its measured capacitance. A new thin, flexible fabric-based IDC sensor is introduced for application on conformal curved surfaces such as an electrical cable surface. A multielectrode IDC and its backplane were fabricated using conductive copper polyester taffeta fabrics that were adhesively bonded to nonconductive polyester fabric. The sensor because of its soft flexible structure eliminates the problem of sensor conductor damage which is common for printed circuit board (PCB) type sensors when conformed to the surface of a cable. It also significantly reduces the airgap between the electrodes and the surface that they must contact in order to measure the capacitance. Airgap reduction and consistency are important in order to accurately predict permittivity variations in cable insulation material due to aging. Both PCB-based sensors and the new fabric-based sensors were built and tested on unaged cables and cables that underwent accelerated aging. Results demonstrate the proposed advantages of the novel fabric-based IDC sensor.

interdigital capacitor sensor, IDC, NDE, PCB senso↗

DOE OSTI2020

Comparative Analysis of Capacitive Sensors with Different Geometrical layouts for Cable Insulation Degradation Detection

This paper presents a comparative analysis between an Interdigital Capacitor (IDC) sensor and a Serpentine Capacitive (SRC) sensor. The effects of electrode layouts on sensor performance are studied by means of finite element simulation where the geometrical dimensions (except electrode length) and material characteristics of both sensors are identical. Conformal IDC and SRC sensors with equal sensor area are modeled on a cable surface. The simulation results show a tradeoff between IDC and SRC sensors in terms of sensitivity and penetration depth. The SRC sensor shows 13.3% increase in sensitivity and 16.8% increase in capacitance compared to the IDC sensor, though the electric field penetration depth of the SRC sensor is 18.8% lower than the IDC sensor. In addition, the effects of change in electrode width, inter-electrode gap, and number of electrodes on SRC and IDC sensor comparative performance are evaluated.

Interdigital Capacitance, Serpentive Capacitive Se↗

DOE OSTI2020

Interdigital Capacitance Sensor for Cable Insulation Test and Monitoring

A substantial body of work suggests feasibility to measure cable jacket and insulation conditions using various forms of interdigital capacitance (IDC) sensors. The sensors can either be used to manually test local cable conditions or as permanently installed sensors. Eligible cables subject to these measurements do not include shielded cables but the set of candidate cables is expanded from only unjacketed cables by the ability to assess insulation condition through the jacket. Dual gap IDC sensors are confirmed to be able to sense the insulation condition beneath a polymer jacket and, moreover, the IDC is the only known way to assess the insulation condition through the jacket. PNNL has filed a patent for this approach and is exploring commercial partnerships to exploit IDC technology for actionable field measurements.

NDE, cable, IDC, capacitance, permittivity, insula↗