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DOE OSTI2021

Upgrade of the ILC Cryomodule

Results of testing modified components for the cryomodule of the International Linear Collider (ILC) are summarized. To reduce the ILC project cost, it is proposed to replace titanium cryomodule components with stainless steel (SS) ones. New bimetallic transitions (Ti/SS, Nb/SS) have been produced by a unique method based on explosion welding. Successive upgrading of these components to the latest version of the Nb/Ti/SS transition element has led to improvement of the ILC cryomodule. This new component resolves problems of residual stress, and its specific design prevents the possibility of a shift due to the difference in the linear expansion coefficients of the constituent metals. Furthermore, leak tests with the He gas revealed no leaks at the background rate of ≈0.2 × 10$^{–10}$ atm cc/s. The test results are very encouraging. The up-to-date design of trimetallic Nb/Ti/SS element promises technologically simpler and less expensive manufacture. Investigations have shown that explosion welding allows unique trimetallic components to be made not only for cryogenic units of accelerators but also for laboratory equipment and for general engineering applications.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Recent Developments in Sensor Technologies for Enabling the Hydrogen Economy

Efforts to create a sustainable hydrogen economy are gaining momentum as governments all over the world are investing in hydrogen production, storage, distribution, and delivery technologies to develop a hydrogen infrastructure. This involves transporting hydrogen in gaseous or liquid form or using carrier gases such as methane, ammonia, or mixtures of methane and hydrogen. Hydrogen is a colorless, odorless gas and can easily leak into the atmosphere leading to economic loss and safety concerns. Therefore, deployment of robust low-cost sensors for various scenarios involving hydrogen is of paramount importance. Here, we review some recent developments in hydrogen sensors for applications such as leak detection, safety, process monitoring in production, transport and use scenarios. The status of methane and ammonia sensors is covered due to their important role in hydrogen production and transportation using existing natural gas and ammonia infrastructure. This review further provides an overview of existing commercial hydrogen sensors and also addresses the potential for hydrogen as an interferent gas for currently used sensors. This review can help developers and users make informed decisions about how to drive hydrogen sensor technology forward and to incorporate hydrogen sensors into the various hydrogen deployment projects in the coming decade.

08 HYDROGEN↗
DOE OSTI2021

Polarimetric Radar Variables in Snowfall at Ka- and W-Band Frequency Bands: A Comparative Analysis

Dual-frequency millimeter-wavelength radar observations in snowfall are analyzed in order to evaluate differences in conventional polarimetric radar variables such as differential reflectivity (ZDR) specific differential phase shift (K DP ) and linear depolarization ratio (LDR) at traditional cloud radar frequencies at Ka and W bands (~35 and ~94 GHz, correspondingly). Low radar beam elevation (~5°) measurements were performed at Oliktok Point, Alaska, with a scanning fully polarimetric radar operating in the horizontal–vertical polarization basis. This radar has the same gate spacing and very close beam widths at both frequencies, which largely alleviates uncertainties associated with spatial and temporal data matching. It is shown that observed Ka- and W-band Z DR differences are, on average, less than about 0.5 dB and do not have a pronounced trend as a function of snowfall reflectivity. The observed Z DR differences agree well with modeling results obtained using integration over nonspherical ice particle size distributions. For higher signal-to-noise ratios, KDP data derived from differential phase measurements are approximately scaled as reciprocals of corresponding radar frequencies indicating that the influence of non-Rayleigh scattering effects on this variable is rather limited. This result is also in satisfactory agreement with data obtained by modeling using realistic particle size distributions. Observed Ka- and W-band LDR differences are strongly affected by the radar hardware system polarization “leak” and are generally less than 4 dB. Smaller differences are observed for higher depolarizations, where the polarization “leak” is less pronounced. Realistic assumptions about particle canting and the system polarization isolation lead to modeling results that satisfactorily agree with observational dual-frequency LDR data.

42 ENGINEERING↗
DOE OSTI2020

Progress Toward Molten Salt Reactor Heat Exchanger On-Line 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, 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

Kimberlina 1.2 Velocity Models and Seismic Data

Kimberlina 1.2 Velocity model and synthetic seismic data, produced in collaboration of teams at the National Energy Technology Laboratory, Los Alamos National Laboratory, and Lawrence Livermore National Laboratory through the National Risk Assessment Partnership. Data is associated with the following publication: Zheng Zhou, Youzuo Lin, Zhongping Zhang, Yue Wu, Zan Wang, Robert Dilmore, and George Guthrie, "A Data-Driven CO2 Leakage Detection Using Seismic Data and Spatial-Temporal Densely Connected Convolutional Neural Networks," International Journal of Greenhouse Gas Control, Vol 90, 2019. The Kimberlina 1.2 Velocity models were produced by Zan Wang, Robert Dilmore, William Harbert, and Lianjie Huang at NETL. The following citations are directly related to the creation of the velocity models: Wang, Z. Harbert, W., Dilmore, R., Huang, L. Modeling of time-lapse seismic monitoring using CO2 leakage simulations for a model CO2 storage site with realistic geology: Application in assessment of early leak-detection capabilities. International Journal of Greenhouse Gas Control. V. 76, September 2018, Pages 39-52. https://doi.org/10.1016/j.ijggc.2018.06.011 Wang, Z., Dilmore, R., Harbert, W. Inferring CO2 saturation from synthetic surface seismic and downhole monitoring data using machine learning for leakage detection at CO2 sequestration sites. International Journal of Greenhouse Gas Control, V. 100, September 2020. https://doi.org/10.1016/j.ijggc.2020.103115 The velocity models were built based on the Kimberlina 1.2 aquifer impact data which is associated with the following publications: Buscheck, T.A., Mansoor, K., Yang, X., Wainwright, H., and Carroll, S. (2019). Downhole pressure and chemical monitoring for CO2 and brine leak detection in aquifers above a CO2 storage reservoir. International Journal of Greenhouse Gas Control. 91. 102812. 10.1016/j.ijggc.2019.102812. Xianjin Yang, Thomas A. Buscheck, Kayyum Mansoor, Zan Wang, Kai Gao, Lianjie Huang, Delphine Appriou, Susan A. Carroll, Assessment of geophysical monitoring methods for detection of brine and CO2 leakage in drinking water aquifers, International Journal of Greenhouse Gas Control, Volume 90, 2019, 102803, ISSN 1750-5836, https://doi.org/10.1016/j.ijggc.2019.102803 The synthetic seismic data was produced by Youzuo Lin and team at LANL, and are associated with the following citations: Jordan, P. D., and J. L. Wagoner. Characterizing Construction of Existing Wells to a CO2 Storage Target: The Kimberlina Site, California. Zheng Zhou, Youzuo Lin, Zhongping Zhang, Yue Wu, Zan Wang, Robert Dilmore, and George Guthrie, "A Data-Driven CO2 Leakage Detection Using Seismic Data and Spatial-Temporal Densely Connected Convolutional Neural Networks," International Journal of Greenhouse Gas Control, Vol 90, 2019.

CO2 Leakage↗
DOE OSTI2020

Vadose Zone Model for B-3A/B Pond for Composite Analysis

The objectives of the vadose modeling for the updated Hanford Site composite analysis (CA) are to simulate the flow and transport of water and radionuclide releases from the surface to the water table and to provide radionuclide transfer rates for the plateau to river (P2R) model, version 8.3 (CP-57037, Model Package Report: Plateau to River Groundwater Model, Version 8.3). Water additions include natural recharge and water discharged to the ground as a result of industrial processes associated with Hanford Site operations. Contaminant sources include radionuclides in water discharged to the ground during operations and radionuclides disposed “dry” in solid waste burial grounds or other means. The following 16 radionuclides were selected for this modeling effort; carbon-14 (C-14), chlorine-36 (Cl-36), tritium (H-3), iodine-129 (I-129), neptunium-237 (Np-237), rhenium-187 (Re-187), strontium-90 (Sr-90), technetium-99 (Tc-99), uranium-232 (U-232), uranium-233 (U-233), uranium-234 (U-234), uranium-235 (U-235), uranium-236 (U-236), uranium-238 (U-238), radium-226 (Ra-226), and thorium-230 (Th-230). The simulation time starts in 1943 and ends at 12070, which is 10,000 years after assumed Hanford Site closure in 2070. The parallel version of the Subsurface Transport Over Multiple Phases (STOMP) simulator officially named the exascale Subsurface Transport Over Multiple Phases (eSTOMP), is used to simulate flow and transport for the vadose models. The documentation for the STOMP code is comprehensive. The theoretical and numerical approaches applied in the STOMP code are documented in a published theory guide (PNNL-12030, STOMP Subsurface Transport Over Multiple Phases Version 2.0 Theory Guide). The code has undergone a rigorous verification procedure against analytical solutions, laboratory-scale experiments, and field-scale demonstrations. The application guide (PNNL-11216, STOMP Subsurface Transport Over Multiple Phases Application Guide) provides instructive examples in the application of the code to classical groundwater problems. The user’s guide (PNNL-15782, STOMP: Subsurface Transport Over Multiple Phases Version 4.0: User’s Guide) describes the general use, input file formatting, compilation, and execution of the code. The primary output of the vadose zone modeling is radionuclide transfer rates to the groundwater for input into the P2R model. The rates will be summed over the 100 by 100 m P2R grid cells that fall within the vadose zone model source domain. The Hanford Site Central Plateau was subdivided into 26 individual vadose zone models, with 13 in the 200 East Area and 13 in the 200 West Area. Waste sites that have a completed performance assessment (PA) or past-leak analysis were not included as sources of radionuclides. Instead the vadose zone to groundwater transfer rates of the Environmental Restoration Disposal Facility, Integrated Disposal Facility, US Ecology, and Waste Management Area C (WMA C) PAs and the past-leak analysis for WMA C were used as direct input to the P2R model. Each of the vadose zone models is documented in separate environmental calculation files (ECFs). This ECF describes the B-3A/B Ponds model. The scope of this ECF is to document the development and results of the B-3 A/B Ponds vadose zone model. CP-63515, Model Package Report: Central Plateau Vadose Zone Models, describes the approach, assumptions, process of determining the number of models required and domain of each model, input data, and processing common to all the models.

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

Vadose Zone Model for SALDS for Composite Analysis

The objectives of the vadose modeling for the updated Hanford Site composite analysis (CA) are to simulate the flow and transport of water and radionuclide releases from the surface to the water table and to provide radionuclide transfer rates for the plateau to river (P2R) model, version 8.3 (CP-57037, Model Package Report: Plateau to River Groundwater Model, Version 8.3). Water additions include natural recharge and water discharged to the ground as a result of industrial processes associated with Hanford Site operations. Contaminant sources include radionuclides in water discharged to the ground during operations and radionuclides disposed “dry” in solid waste burial grounds or other means. The following 16 radionuclides were selected for this modeling effort: carbon-14 (C-14), chlorine-36 (Cl-36), tritium (H-3), iodine-129 (I-129), neptunium-237 (Np-237), rhenium-187 (Re-187), strontium-90 (Sr-90), technetium-99 (Tc-99), uranium-232 (U-232), uranium-233 (U-233), uranium-234 (U-234), uranium-235 (U-235), uranium-236 (U-236), uranium-238 (U-238), radium-226 (Ra-226), and thorium-230 (Th-230). The simulation time starts in 1943 and ends at 12070, which is 10,000 years after assumed Hanford Site closure in 2070. The parallel version of the Subsurface Transport Over Multiple Phases (STOMP1) simulator, officially named the exascale Subsurface Transport Over Multiple Phases (eSTOMP) is used to simulate flow and transport for the vadose models. The documentation for the STOMP code is comprehensive. The theoretical and numerical approaches applied in the STOMP code are documented in a published theory guide (PNNL-12030, STOMP Subsurface Transport Over Multiple Phases Version 2.0 Theory Guide). The code has undergone a rigorous verification procedure against analytical solutions, laboratory-scale experiments, and field-scale demonstrations. The application guide (PNNL-11216, STOMP Subsurface Transport Over Multiple Phases Application Guide) provides instructive examples in the application of the code to classical groundwater problems. The user’s guide (PNNL-15782, STOMP: Subsurface Transport Over Multiple Phases Version 4.0: User’s Guide) describes the general use, input file formatting, compilation, and execution of the code. The primary output of the vadose zone modeling is radionuclide transfer rates to the groundwater for input into the P2R model. The rates will be summed over the 100 by 100 m P2R grid cells that fall within the vadose zone model source domain. The Hanford Site Central Plateau was subdivided into 26 individual vadose zone models, with 13 in the 200 East Area and 13 in the 200 West Area. Waste sites that have a completed performance assessment (PA) or past-leak analysis were not included as sources of radionuclides. Instead the vadose zone to groundwater transfer rates of the Environmental Restoration Disposal Facility, Integrated Disposal Facility, US Ecology, and Waste Management Area C (WMA C) PAs and the past-leak analysis for WMA C were used as direct input to the P2R model. Each of the vadose zone models is documented in separate environmental calculation files (ECFs). This ECF describes the State-Approved Land Disposal Site (SALDS) model. The scope of this ECF is to document the development and results of the SALDS vadose zone model. CP-63515, Model Package Report: Central Plateau Vadose Zone Models, describes the approach, assumptions, process of determining the number of models required and domain of each model, input data, and processing common to all the models.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Updated Estimate of Tritium Permeation from TPBAR Disposal Containers in ILV (U)

A tritium source term analysis was performed for TPBAR disposal in the E-Area Intermediate Level Vaults for the E-Area Low-Level Waste Facility Performance Assessment (PA). This analysis is based on an earlier source term analysis which treated the bulk oft he tritium residual as tightly bound by the TPBAR getter material, with only a small fraction existing as tritiated moisture in the lithium aluminate ceramic pellets. Together with atmospheric moisture trapped in the free volume, the tritiated water vapor is assumed to corrode steel surfaces inside the disposal container, covering them with a magnetite film while generating hydrogen. The carbon steel walls of the disposal container are permeable to hydrogen, providing a path way for tritium to escape containment. The rate of hydrogen generation is assumed to be limited by the rate of corrosion, which is assumed to be governed by parabolic reaction kinetics obtained from the literature. This relies on the further assumption that the water vapor consumed by the corrosion reaction is continually replaced by moisture from the lithium aluminate pellets until all of that moisture is gone. In addition to tritium permeation, the analysis also includes a slow leak through the disposal container walls at the maximum allowable leak rate, 1 x 1CH standard cm3/s. Results were obtained for four different combinations of internal and container wall temperatures, established in an earlier thermal analysis that considered two different vault loadings and two different TPBAR activity levels. Instantaneous release rates for these four cases are plotted in Figure ES-1 below

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Tritiated Sulfur Hexafluoride Disposition Strategies

Tritium (T 2 ) is a radioactive isotope of hydrogen that is produced in nuclear fission reactions and is often used in nuclear fusion reactions and accelerator-based applications for medical isotope production. As a hydrogen isotope, tritium can readily bind to hydroxyl radicals (OH), forming tritiated water (HTO or T 2 0), and to carbon atoms. Tritium decays to helium-3 ( 3 He) via beta-decay with max decay energy of 18.6 keV. While it is not an external radiation hazard, it can be an internal radiation hazard if tritium is inhaled, ingested, or absorbed through the skin. In applications where tritium is handled, tritium confinement is performed using different barriers to minimize releases to the environment. For gaseous (elemental), liquid (oxide), and metal (hydride) tritium, process piping and components provide the primary confinement function. Secondary tritium confinement is typically provided by inert (i.e. non-flammable gases such as nitrogen, argon, or helium) gloveboxes which are connected to a tritium stripper system. Primary tritium confinement barriers typically produce low volumes of high tritium concentrations of tritiated methane from carbon in steels or organic materials along with tritiated water/tritium oxide (e.g. HTO) and tritiated ammonia from reactions with oxygen and nitrogen. Tritium escaping primary confinement into secondary confinement atmospheres (e.g. gloveboxes) produce higher volumes of lower activity contamination than found in process piping. Tritium contamination also occurs by leaks or tritium permeation/diffusion through confinement materials. Tritium from inside primary confinement barriers will diffuse or leak out of the primary confinement barrier and usually into the air, if the system is inside an air hood or ventilated hot cell, or into the secondary confinement (e.g. glovebox) atmosphere which is either exhausted or stripped based on the function of the secondary confinement (glovebox) system. Accelerator based processes for medical isotope production represent an atypical tritium contamination challenge. In medical isotope production, deuterium supply gas is ionized and accelerated to a tritium gas target to produce neutrons that are then used to produce the medical isotopes through additional nuclear fission reactions. To create large voltage differentials for accelerator operations, an electrical insulation medium is needed to prevent or rapidly quench electric discharges. A common electrical insulation medium utilized in accelerator applications is sulfur hexafluoride (SF 6 ) gas. SF 6 has a high dielectric strength and allows for the construction of smaller accelerator systems compared to other electrical insulation mediums such as air or dry nitrogen. Due to tritium permeation/diffusion through accelerator process and confinement materials, there is the possibility that tritium can contaminate the electrical insulation medium of the accelerator. Tritium contaminated SF 6 creates a material without any obvious processes for managing the contamination, reuse, or disposal of the used SF 6 . This document will discuss possible management strategies for tritium contaminated SF 6 for accelerator-based processes for Molybdenum-99 (Mo-99) production.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Produce ZrH Moderator Material

This reports complete Milestone M2.2.3 Produce zirconium hydride moderator material. In this milestone, we report the successful fabrication of FeCrAl alloys cladded zirconium hydride moderator. Different types of crucible designs were presented, including the basic design with bar cladding material, basic design with tube cladding material, and crucible design with position holding function. Mo and FeCrAl were used as the trial cladding materials. The welding techniques and procedures were reported and discussed. Totally three welding techniques were adopted in the development of moderator cladding, and they are electron beam welding (EBW), laser welding (LW), and gas tungsten arc welding (GTAW). After welding, all cladded crucibles were evaluated with two kinds of leak testing, the helium leak test for minor leakage and the bubble test for major leakage. Due to the concern of the poor neutronics performance, Mo was not ideal for future moderator cladding application. Therefore, detailed characterization of the Mo cladded zirconium hydride was not pursued. Instead, the characterization of FeCrAl cladded zirconium hydride was performed. We discussed two material conditions (i.e., as machined and pre-oxidized conditions) prior to the cladding process, evaluated thermal stability of cladded zirconium hydride moderator through directly measuring hydrogen release, and characterized the zirconium hydride following the thermal desorption measurement. The results showed pre-oxidized FeCrAl is capable of efficiently preventing hydrogen release from the moderator assembly.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Review of Release Behavior of Hydrogen & Natural Gas Blends from Pipelines

Hydrogen can be used to reduce carbon emissions by blending into other gaseous energy carriers, such as natural gas. However, hydrogen blending into natural gas has important implications for safety which need to be evaluated. Hydrogen has different physical properties than natural gas, and these properties affect safety evaluations concerning a leak of the blended gas. The intent of this report is to begin to investigate the safety implications of blending hydrogen into the natural gas infrastructure with respect to a leak event from a pipeline. A literature review was conducted to identify existing data that will better inform future hazard and risk assessments for hydrogen/natural gas blends. Metrics with safety implications such as heat flux and dispersion behavior may be affected by the overall blend ratio of the mixture. Of the literature reviewed, there was no directly observed separation of the hydrogen from the natural gas or methane blend. No literature was identified that experimentally examined unconfined releases such as concentration fields or concentration at specific distances. Computational efforts have predicted concentration fields by modified versions of existing engineering models, but the validation of these models is limited by the unavailability of literature data. There are multiple literature sources that measured flame lengths and heat flux values, which are both relevant metrics to risk and hazard assessments. These data can be more directly compared to the outputs of existing engineering models for validation.

03 NATURAL GAS↗
DOE OSTI2021

Validation of the HyRAM+ physics models for use with propane

The Hydrogen Risk Assessment Model Plus (HyRAM+) toolkit combines quantitative risk assessment with simulations of unignited dispersion, ignited turbulent diffusion flames, and indoor accumulation with delayed ignition of fuels. HyRAM+ is differentiated from HyRAM in that it includes models and leak data for other alternate fuels. The models of the physical phenomena need to be validated for each of the fuels in the toolkit. This report shows the validation for propane which is being used as a surrogate for autogas, which is a mixture of propane and butane and used in internal combustion engines in vehicles. For flame length comparisons, five previously published experiments from peer reviewed journals were used to validate our models. The validation looked at flame lengths and flame widths with respect to different leak diameters, mass flow rates, and source pressures. Most of the sources included more than one set of experimental data, which were collected using different methods (CCD cameras, IR visualization etc.). In general, HyRAM+ overpredicts the flame lengths by around 65%. For heat and radiation models, we compared the heat flux and radiation data reported from two different sources to the values calculated by HyRAM+. For higher mass flow rates, the HyRAM+ calculated flame length results gave a better estimate of what is found in the experiments (65% error), but a higher error (85%) is observed between the HyRAM+ calculated lengths and the experimental flame lengthsfor lower mass flows. Some differences can be attributed to outdoor environmental effects (i.e. wind speed) and uncertainties in jet flame shapes. The propane flame trajectory is predicted for a high Reynolds number case with Re = 12,500 and a low Reynolds number case where Re = 2,000. The Re=12,500 case which is momentum dominated matches well with the experimental flame trajectory, but the agreement for the bouancy driven low Reynolds number case is not as good. Dispersion modeling for unignited propane was also analyzed. We compared the mole fraction, mixture fraction, mean velocity, concentration half width, and inverse mass concentration over an axial distance from different credible journals to the values calculated by HyRAM+. The results display good agreement but generally, HyRAM+ predicts a wider profile for mole fraction and mixture fraction experiments. Overall, HyRAM+’s results are reasonable for predicting the flame length, heat flux, flame trajectory, and dispersion for propane and can be used in risk analyses

08 HYDROGEN↗
DOE OSTI2021

Direct Subsurface Measurements through Precise Micro Drilling

Wellbore integrity is a significant problem in the U.S. and worldwide, which has serious adverse environmental and energy security consequences. Wells are constructed with a cement barrier designed to last about 50 years. Indirect measurements and models are commonly used to identify wellbore damage and leakage, often producing subjective and even erroneous results. The research presented herein focuses on new technologies to improve monitoring and detection of wellbore failures (leaks) by developing a multi-step machine learning approach to localize two types of thermal defects within a wellbore model, a prototype mechatronic system for automatically drilling small diameter holes of arbitrary depth to monitor the integrity of oil and gas wells in situ, and benchtop testing and analyses to support the development of an autonomous real-time diagnostic tool to enable sensor emplacement for monitoring wellbore integrity. Each technology was supported by experimental results. This research has provided tools to aid in the detection of wellbore leaks and significantly enhanced our understanding of the interaction between small-hole drilling and wellbore materials.

42 ENGINEERING↗
DOE OSTI2021

NRAP-Open-IAM: FutureGen2 Component Models

This report describes the development and testing of three component models for NRAP-Open-IAM, the National Risk Assessment Partnership’s open-source integrated assessment model. The FutureGen2 Lookup Table Reservoir component model is based on interpolation of data from a set of lookup tables. The lookup tables contain pressures and saturations predicted by multiphase flow simulations performed with a reservoir simulator. The FutureGen2 Above Zone Monitoring Interval (AZMI) component is a surrogate model that can be used to estimate the impact that carbon dioxide (CO 2 ) and brine leaks from the CO 2 storage reservoir at the FutureGen 2.0 site might have had on overlying aquifers or monitoring units were a leak to occur. The model estimates the size of “impact plumes” according to five metrics: pH, Total Dissolved Solids (TDS), pressure, dissolved CO 2 and temperature. The FutureGen2 Aquifer component is similar, but is limited to four metrics: pH, Total Dissolved Solids (TDS), pressure, and dissolved CO 2 . The input parameters for each model are the same, but the Aquifer component is applicable to depths between 100 m and 700 m and the AZMI component is applicable from depths between 700 m and 1050 m.

42 ENGINEERING↗
DOE OSTI2021

Analysis of the MST-16 crimp process on cold 304L stainless steel

The purpose of this report is to assess the quality of the MST-16 crimp process through a series of cold experiments and metallographic analyses. Common practice in MST-16 uses a mechanical crimp on 304L stainless steel tubes to prevent radioactive contamination from escaping the tube interior for a variety of experiments. The crimped tubes must pass a leak check to demonstrate their radiological safety. Cold (i.e. non-radioactive samples) 304L tube samples were tested using two different approved crimping devices to assess the quality of the crimps. Each crimp was leak checked, followed by destructive metallographic analysis to determine the quality of both the crimp equipment and procedures used by MST-16 personnel.

42 ENGINEERING↗
DOE OSTI2022

NRAP-Open-IAM: Generic Aquifer Component Development and Testing

The Generic Aquifer Model calculates the concentrations of dissolved salt and dissolved CO 2 surrounding a leaking legacy well. The Generic Aquifer model can also estimate the size of an “impact plume” where concentration changes exceed user-specified thresholds. The model is a component of NRAP-Open-IAM, an open-source Integrated Assessment Model (IAM) developed by the National Risk Assessment Partnership (NRAP) to perform risk assessment for geologic CO 2 storage. The input parameters were selected to cover a wide range of groundwater aquifers and leakage rates. The generic aquifer model was developed using a generative adversarial deep learning network, trained using a large synthetic dataset of STOMP multiphase flow simulations. The deep learning model predictions of dissolved salt and dissolved CO 2 in the aquifer compare well to the original STOMP simulation results. The extent of aquifer impacted by leaking CO 2 or brine is calculated using a user-defined mass fraction threshold. The aquifer impact volumes calculated based on STOMP simulation results compare well to those calculated based on the deep learning model. In a provided python script, gridded observation results from the generic aquifer component of NRAP-Open-IAM are converted to HDF5 format files for monitoring design with the DREAM code.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

MELCOR Accident Progression and Source Term Demonstration Calculations for a FHR

MELCOR is an integrated thermal hydraulics, accident progression, and source term code for reactor safety analysis that has been developed at Sandia National Laboratories for the United States Nuclear Regulatory Commission (NRC) since the early 1980s. Though MELCOR originated as a light water reactor (LWR) code, development and modernization efforts have expanded its application scope to include non-LWR reactor concepts. Current MELCOR development efforts include providing the NRC with the analytical capabilities to support regulatory readiness for licensing non-LWR technologies under Strategy 2 of the NRC's near- term Implementation Action Plans. Beginning with the Next Generation Nuclear Project (NGNP), MELCOR has undergone a range of enhancements to provide analytical capabilities for modeling the spectrum of advanced non-LWR concepts. This report describes the generic plant model developed to demonstrate MELCOR capabilities to perform fluoride-salt-cooled high-temperature reactor (FHR) safety evaluations. The generic plant model is based on publicly-available FHR design information. For plant aspects (e.g., reactor building leak rate and details of the cover-gas system) that are not described in the FHR references, the analysts made assumptions needed to construct a MELCOR full-plant model. The FHR model uses a TRi-structural ISOtropic (TRISO)-particle fuel pebble-bed reactor with a primary system rejecting heat to two coiled tube air heat ex changers. Three passive direct reactor auxiliary cooling systems provide heat removal to supplement or replace the emergency secondary system heat removal during accident conditions. Surrounding the reactor vessel is a low volume reactor cavity that insulates the reactor with fire bricks and thick concrete walls. A refractory reactor liner system provides water cooling to reduce the concrete wall temperatures. Example calculations are performed to show the plant response and MELCOR capabilities to characterize a range of accident conditions. The accidents selected for evaluation consider a range of degraded and failed modes of operation for key safety functions providing reactivity control, the primary system decay heat removal and also a piping leak of the line to the coolant drain tank.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Hydrogen Plus Other Alternative Fuels Risk Assessment Models (HyRAM+) Version 4.1 Technical Reference Manual

The HyRAM+ software toolkit provides a basis for conducting quantitative risk assessment and consequence modeling for hydrogen, methane, and propane systems. HyRAM+ is designed to facilitate the use of state-of-the-art models to conduct robust, repeatable assessments of safety, hazards, and risk. HyRAM+ integrates deterministic and probabilistic models for quantifying accident scenarios, predicting physical effects, characterizing hazards (thermal effects from jet fires, overpressure effects from delayed ignition), and assessing impacts on people. HyRAM+ is developed at Sandia National Laboratories to support the development and revision of national and international codes and standards, and to provide developed models in a publicly-accessible toolkit usable by all stakeholders. This document provides a description of the methodology and models contained in HyRAM+ version 4.1. The two most significant changes for HyRAM+ version 4.1 from HyRAM+ version 4.0 are direct incorporation of unconfined overpressure into the QRA calculations and modification of the models for cryogenic liquid flow through an orifice. In QRA mode, the user no longer needs to input peak overpressure and impulse values that were calculated separately; rather, the unconfined overpressure is estimated for the given system inputs, leak size, and occupant location. The orifice flow model now solves for the maximum mass flux through the orifice at constant entropy while conserving energy, which does not require a direct speed of sound calculation. This does not affect the mass flow for all-gaseous releases; the method results in the same speed of sound for choked flow. However, this method does result in a higher (and more realistic) mass flow rate for a given leak size for liquid releases than was previously calculated.

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